Suzuki Wagon R+ RB310 RB412 RB413D Service Manual 99501U83E50-01E

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: Wagon R+ (RB310/RB412/RB413D) of and after the vehicle identification number below.

TSM0HAF685G069865~

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.

NOTE: “SUZUKI Dealers” means Authorized Suzuki Service Workshop (in Europe).

RELATED MANUAL:

Manual Name Manual No. RB413 SERVICE MANUAL 99500-83E00-01E Wagon R+ (RB413) SUPPLEMENTARY SERVICE MANUAL 99501U83E00-01E RB310 SERVICE MANUAL 99500U83E10-01E Wagon R+ (RB310/RB413) SUPPLEMENTARY SERVICE MANUAL 99501U83E10-01E Wagon R+ (RB310/RB413) SUPPLEMENTARY SERVICE MANUAL 99501U83E20-01E Wagon R+ (RB310/RB413/RB413D) SUPPLEMENTARY SERVICE MANUAL Ignis (RM413D)/Wagon R+ (RB413D) SUPPLEMENTARY SERVICE MANUAL FOR Z13DT ENGINE AND M/T Wagon R+ (RB310/RB412/RB413D) WIRING DIAGRAM MANUAL 99512U83EA0-669

99501U83E30-01E

99501U86G30-01E

RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE

SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle's exact specifications.

A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently available in the market. Using these parts and accessories can affect the vehicle performance and shorten its useful life. Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty.

Non-Genuine SUZUKI Parts and Accessories

Some parts and accessories may be approved by certain authorities in your country. Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genuine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.

Re-use of Genuine SUZUKI Parts and Accessories

The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbidden:

1) Airbag components and all other pyrotechnic items, including their components (e.g. cushion, control devices and sensors)

2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors)

The air bag and seat belt pretensioner components contain explosive chemicals. These components should be removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explosion before scrapping.

*The parts remanufactured under SUZUKI’s approval can be used as genuine SUZUKI parts in Europe.

RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE

SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle's exact specifications.

A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently available in the market. Using these parts and accessories can affect the vehicle performance and shorten its useful life. Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty.

Non-Genuine SUZUKI Parts and Accessories

Some parts and accessories may be approved by certain authorities in your country. Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genuine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.

Re-use of Genuine SUZUKI Parts and Accessories

The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbidden:

1) Airbag components and all other pyrotechnic items, including their components (e.g. cushion, control devices and sensors)

2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors)

The air bag and seat belt pretensioner components contain explosive chemicals. These components should be removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explosion before scrapping.

*The parts remanufactured under SUZUKI’s approval can be used as genuine SUZUKI parts in Europe.

RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE

SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle's exact specifications.

A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently available in the market. Using these parts and accessories can affect the vehicle performance and shorten its useful life. Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty.

Non-Genuine SUZUKI Parts and Accessories

Some parts and accessories may be approved by certain authorities in your country. Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genuine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.

Re-use of Genuine SUZUKI Parts and Accessories

The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbidden:

1) Airbag components and all other pyrotechnic items, including their components (e.g. cushion, control devices and sensors)

2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors)

The air bag and seat belt pretensioner components contain explosive chemicals. These components should be removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explosion before scrapping.

*The parts remanufactured under SUZUKI’s approval can be used as genuine SUZUKI parts in Europe.

Steering, Suspension, Wheels and Tires 3 3B 6K4 Front Wheel Alignment 3A Charging System (Z13DT Engine Manual Rack and Pinion 3B 3C 7A3 Electrical Power Steering (EPS) System (If Equipped) Steering Wheel and Column 3C Exhaust System (Z13DT Engine Model)* 6K3 3F 7C3 Front Suspension 3D Exhaust System (Z10XEP/Z12XEP Rear Suspension 3E 4A3 7C5 Wheels and Tires 3F TRANSMISSION, CLUTCH AND

DRIVE SHAFT AND PROPELLER SHAFT 4A5 8

Front Drive Shaft (Z13DT Engine Model) 4A3 Manual Transaxle (Z13DT Engine Front Drive Shaft (Z10XEP Engine Model) Front Drive Shaft (Z12XEP Engine Model)

BRAKES 5 5E1 8G4

Brakes Pipe/Hose/Master Cylinder 5A Clutch (Z13DT Engine Model)* 7C3 Front Brake 5B Clutch (Z10XEP Engine Model) 7C4 6-3 9 Parking and Rear Brake 5C Clutch (Z12XEP Engine Model) 7C5 6-4 10 Antilock Brake System (ABS) 5E1 BODY ELECTRICAL SERVICE 8 6A3 10A ENGINE Wiring Diagram 8A 6A4 10B Engine General Information and Diagnosis (Z13DT Engine)* Engine General Information and Diagnosis (Z10XEP/Z12XEP Engines) Engine Mechanical (Z13DT Engine)* 6A3 Engine Mechanical (Z10XEP/Z12XEP Engines) Engine Cooling (Z13DT Engine Model)* 6B3 BODY SERVICE 9 Engine Cooling (Z10XEP/Z12XEP Engine Models) Engine Fuel (Z13DT Engine Model)* 6C3 Air Bag System 10B Engine Fuel (Z10XEP/Z12XEP Engine Model)

3B1

4A4

4A5

6-3

6-4

6A4

6B4

6C4

(Z13DT Engine Model)*

(Z10XEP/Z12XEP Engine Models)

Engine Models) Cranking System (Z13DT Engine Model)* 6G3 3 6H4 Cranking System (Z10XEP/Z12XEP

Engine Models)

Model)* Charging System (Z10XEP/Z12XEP

Engine Models)

DIFFERENTIAL

Model)* Manual Transaxle (Z10XEP Engine

Model) Manual Transaxle (Z12XEP Engine

Model)

Lighting System 8B 6B3 Instrumentation/Driver Information 8C 6B4 Windows, Mirrors, Security and Locks 8D 6C3 Immobilizer Control System (Z13DT Engine Model) Immobilizer Control System (Z10XEP/ Z12XEP Engine Models)

RESTRAINT SYSTEM 10 Seat Belt 10A

6E3

6E4

6F4

6G4

6H3

6H4

6K4

7A3

7A4

7A5

8G3

8G4

0A 6E3

6F4

1B 6G4

3A 6K3

3B1

3D 7A4 3E 7A5

7C4

4A4

8A

5 8B 5A 8C 5B 8D 5C 8G3

6C4

NOTE:

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

• For the screen toned sections with “*” in the above table, refer to the same section of the Related Manual “IGNIS (RM413D)/WAGON R+ (RB413D) SUPPLEMENTARY SERVICE MANUAL FOR Z13DT ENGINE AND M/T” mentioned in FOREWORD of this manual.

GENERAL INFORMATION 0A-1

SECTION 0A

GENERAL INFORMATION

NOTE:

For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Manual mentioned in “FOREWORD” of this manual.

CONTENTS

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

Precautions...................................................... 0A-*

Precaution for Vehicles Equipped with a

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

Diagnosis................................................... 0A-*

Servicing and handling .............................. 0A-*

General Precautions ..................................... 0A-*

Precaution for CAN Communication

System .......................................................... 0A-*

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

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

Precaution for Installing Mobile

Communication Equipment ........................... 0A-*

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

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

Open circuit check..................................... 0A-*

Continuity check ........................................ 0A-*

Voltage check............................................ 0A-*

Short circuit check (wire harness to

ground) ...................................................... 0A-*

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

Identification Information...............................0A-2

Vehicle Identification Number ....................... 0A-2

Engine Identification Number........................ 0A-2

Transmission Identification Number.............. 0A-2

Warning, Caution and Information Labels....0A-3

Vehicle Lifting Points ..................................... 0A-*

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

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

Abbreviations and Symbols May be

Used in This Manual .......................................0A-4

Abbreviations ................................................ 0A-4

Symbols .........................................................0A-*

Wire Color Symbols .......................................0A-*

Fastener Information ...................................... 0A-*

Metric Fasteners Information .........................0A-*

Fastener Strength Identification .....................0A-*

Standard Tightening Torque ..........................0A-*

0A

0A-2 GENERAL INFORMATION

Identification Information

Vehicle Identification Number

The number is punched on front dash panel in engine room.

Engine Identification Number

The number is punched on cylinder block.

Transmission Identification Number

The number is located on the transmission case.

[A]: For Z10XEP engine

[B]: For Z12XEP engine / Z13DT engine

GENERAL INFORMATION 0A-3

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.

NOTE:

Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.

1. Air bag label on back side of engine hood (if equipped) 7. Air bag label on passenger air bag (inflator) module

2. Air bag label on sun visor 8. Air bag label on SDM

3. Pretensioner label on seat belt retractor 9. Air bag label on side air bag (inflator) module

4. Tire information placard 10. Side sensor label

5. Air bag label on driver air bag (inflator) module 11. Air bag label on pillar (both right and left)

6. Air bag label on combination switch and contact coil assembly

0A-4 GENERAL INFORMATION

Abbreviations and Symbols May be Used in This Manual

Abbreviations

ABS Anti-lock Brake System AT DC After Top Dead Center API American Petroleum Institute AT F 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 APP sensor Accelerator Pedal Position Sensor HO2S Heated Oxygen Sensor 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) DOHC Double Over Head Camshaft

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

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 PPS Pedal Position Sensor

(Air temperature Sensor, ATS)

Sensor, AFS, Air Flow Meter, AFM)

sor (Pressure Sensor, PS)

(Multipoint Fuel Injection)

(“SERVICE ENGINE SOON” Light)

(Self-Diagnosis Function)

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

(Air bag controller, Air bag control module)

SFI Sequential Multiport Fuel Injection

S

SOHC Single Over Head Camshaft SOI Start of Injection SVS indicator lamp

Service Vehicle Soon Indicator lamp

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

GENERAL INFORMATION 0A-5

0A-6 GENERAL INFORMATION

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 Connectors” 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.

• 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

NOTE:

For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Manual mentioned in “FOREWORD” of this manual.

CONTENTS

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

Maintenance Schedule Under Normal

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

Maintenance Recommended Under Severe

Driving Conditions .........................................0B-6

Maintenance Service.......................................0B-7

Engine Accessory Drive Belt Inspection

(Z10XEP / Z12XEP Engines) ........................0B-7

Engine Accessory Drive Belt Replacement

(Z10XEP / Z12XEP Engines) ........................0B-7

Engine Accessory Drive Belt Inspection

(Z13DT Engine)............................................. 0B-*

Engine Accessory Drive Belt Replacement

(Z13DT Engine)............................................. 0B-*

Engine Oil and Oil Filter Replacement

(Z10XEP / Z12XEP Engines) ........................0B-7

Engine Oil and Oil Filter Replacement

(Z13DT Engine)............................................. 0B-*

Engine Coolant Replacement .......................0B-9

Exhaust System Inspection........................... 0B-*

Spark Plugs Replacement.............................0B-9

Air Cleaner Filter Inspection

(Z10XEP / Z12XEP Engines) ........................0B-9

Air Cleaner Filter Replacement

(Z10XEP / Z12XEP Engines) ......................0B-10

Air Cleaner Filter Inspection

(Z13DT Engine) .............................................0B-*

Air Cleaner Filter Replacement

(Z13DT Engine) .............................................0B-*

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

Fuel Filter Replacement

(Z13DT Engine) .............................................0B-*

Water Draining of Fuel Filter

(Z13DT Engine) .............................................0B-*

Fuel Tank Inspection......................................0B-*

Brake Discs and Pads (Front) Inspection ......0B-*

Brake Drums and Shoes (Rear)

Inspection.......................................................0B-*

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

Brake Fluid Replacement...............................0B-*

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

Clutch Inspection ........................................0B-10

Tires Inspection..............................................0B-*

Wheel Discs Inspection..................................0B-*

Wheel Bearing Inspection ..............................0B-*

Suspension System Inspection......................0B-*

Steering System Inspection ...........................0B-*

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

Manual Transaxle Oil Inspection

(Z10XEP Engine Model) ............................. 0B-10

0B-2 MAINTENANCE AND LUBRICATION

Manual Transaxle Oil Replacement

(Z10XEP Engine Model) ............................. 0B-10

All Latches, Hinges and Locks Inspection .....0B-*

Final Inspection ...............................................0B-*

Recommended Fluids and Lubricants ....... 0B-11

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.

Z10XEP / Z12XEP Engine Models:

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

Interval

ENGINE

Engine accessory drive belt – I – I – R

Engine oil and oil filter

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

IGNITION SYSTEM

✱Spark

plugs

FUEL SYSTEM

Air cleaner filter

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

EMISSION CONTROL SYSTEM

✱Fuel evaporative emission control system – – – – – I

When unleaded fuel is used – – R – – R 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

With a synthetic engine oil of oil grade: ACEA A3, and oil viscosity: SAE 0W-30, 0W-40, 5W-30, 5W-40

Paved-road I I R I I R

Dusty conditions

R R R R R R

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 ✱ (asterisk) should be performed by odometer reading only.

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

0B-4 MAINTENANCE AND LUBRICATION

Z13DT Engine Model:

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

Interval

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

ENGINE

Engine accessory drive belt – I – I – I

Replace every 150,000 km (90,000 miles) or

120 months Engine oil and oil filter

With a synthetic engine oil of oil grade: ACEA B3, and oil viscosity: SAE 0W-30, 0W-40, 5W-

R R R R R R 30, 5W-40 With engine oils other than specified synthetic engine oils

Replace every 7,500 km (4,500 miles) or 6

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

FUEL SYSTEM

Air cleaner filter – – R – – R Fuel lines and connections – I – I – I Fuel filter – R – R – R

Drain water every 15,000 km (9,000 miles)

or 12 months Fuel tank – – I – – I

NOTE:

• “R”: Replace or change

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

• Some maintenance items are required to be serviced at times other than the regular maintenance times shown at the top of above table. These items can be serviced at an earlier service opportunity according to customer’s maintenance convenience. Their next maintenance service should be done within the specified period.

MAINTENANCE AND LUBRICATION 0B-5

Z10XEP / Z12XEP / Z13DT Engine Models:

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

Interval

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

BRAKE

Brake discs and pads (thickness, wear, damage) I I I I I I 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 – I – I – I Tires (wear, damage, rotation)/wheels (damage) I I I I I I Suspension system (tightness, damage, rattle, breakage) – I – I – I Steering system (tightness, damage, breakage, rattle) – I – I – I Manual Transaxle oil (for Z10XEP engine model only)

(I: 15,000 km only) I – R – – R

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

NOTE:

• “R”: Replace or change

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

0B-6 MAINTENANCE AND LUBRICATION

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

– B C D – – – – Engine accessory drive belt

A – C D E F – H

A – C D E – – H Z13DT engine

– – C – – – – – Air cleaner filter ✱1

A B C – E F – H Spark plugs R

– B C D – – – H Wheel bearings I

– B – D E – – H Drive shafts I

– B – – E – – H

– – CD – – – – Ventilator air filter ✱2 (if equipped)

Engine oil and oil filter

Manual transaxle oil (for Z10XEP engine model only)

Maintenance

Z10XEP / Z12XEP engines

Maintenance

Operation

Maintenance Interval

I

R

I

R

I

R

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

Every 7,500 km (4,500 miles) or 6 months

Every 2,500 km (1,500 miles) 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: Every 30,000 km (18,000 miles) or 24 months reckoning from 0 km (0 miles) or 0 month Every 15,000 km (9,000 miles) or 12 months Every 45,000 km (27,000 miles) or 36 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.

Maintenance Service

Engine Accessory Drive Belt Inspection (Z10XEP / Z12XEP Engines)

WARNING:

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

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

MAINTENANCE AND LUBRICATION 0B-7

Engine Accessory Drive Belt Replacement (Z10XEP / Z12XEP Engines)

Replace belt with new one referring to “Accessory Drive Belt Removal and Installation” in Section 6B4.

Engine Oil and Oil Filter Replacement (Z10XEP / Z12XEP Engines)

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) – 6) outlined below must be performed with ENGINE NOT RUNNING. For step 7), 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) Remove oil filter element. a) Place oil collecting basin under filter. b) Loosen and remove oil filter housing cover (1).

1

0B-8 MAINTENANCE AND LUBRICATION

2

c) Pull out oil filter element (2) from cover.

2) Drain engine oil by removing drain plug (1).

3) After draining oil, wipe drain plug clean and replace seal ring with a new one. Reinstall drain plug, and tighten it securely as specified below.

Tightening torque Engine oil drain plug (a): 10 N·m (1.0 kg-m, 7.5 lb-ft)

1

4) Install oil filter element.

a) Replace seal ring (1) of oil filter housing cover (3) with new

2

1

3

one and apply engine oil to seal ring.

b) Install new oil filter element (2) to cover.

c) Install oil filter housing cover with element.

Tightening torque Oil filter housing cover (a): 10 N·m (1.0 kg-m, 7.5 lb-ft)

(a)

[A]

SAE 0W-30, 0W-40

SAE 5W-30, 5W-40

-30

-20-4-101403210502068308640

-22CF

12

104

MAINTENANCE AND LUBRICATION 0B-9

5) Replenish oil until oil level is brought to FULL level mark on dipstick. (for Z10XEP engine about 3.0 liters (5.3 lmp pt.), for Z12XEP engine about 3.5 liters (6.2 lmp pt.)) The filler inlet is by the engine oil filter. Use specified engine oil. Select the appropriate oil viscosity according to the proper engine oil viscosity chart [A].

NOTE:

Note that the amount of oil required when actually changing oil may somewhat differ from the data depending on various conditions (temperature, viscosity, etc.)

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

7) 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

2. Low level mark

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.

Change engine coolant with new one referring to “Cooling System Flush and Refill” in Section 6B4 (Z10XEP / Z12XEP engines) or 6B3 (Z13DT engine).

Spark Plugs Replacement

Replace spark plugs with new ones referring to “Spark Plugs Removal and Installation” in Section 6F4.

Air Cleaner Filter Inspection (Z10XEP / Z12XEP Engines)

Check air cleaner filter for dirt and damage, and clean if necessary referring to “Air Cleaner Element Inspection and Cleaning” in Section 6A4.

0B-10 MAINTENANCE AND LUBRICATION

Air Cleaner Filter Replacement (Z10XEP / Z12XEP Engines)

Replace air cleaner filter with new one referring to “Air Cleaner Element Removal and Installation” in Section 6A4.

Clutch Inspection

For Z10XEP / Z12XEP engine models:

Check clutch pedal for free travel referring to “Clutch Pedal Free Travel Check” in Section 7C4 (Z10XEP engine model) or Section 7C5 (Z12XEP engine model). Adjust or correct if necessary.

For Z13DT engine model:

Check clearance between cable nut and release shaft referring to “Clutch Cable Adjustment” in Section 7C3 (Z13DT engine model). Adjust or correct if necessary.

Manual Transaxle Oil Inspection (Z10XEP Engine Model)

1) Inspect transaxle 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 transaxle.

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 7A4 (Z10XEP engine model).

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

Manual Transaxle Oil Replacement (Z10XEP Engine Model)

Replace manual transaxle oil referring to “Manual Transaxle Oil Change” in Section 7A4 (Z10XEP engine model).

MAINTENANCE AND LUBRICATION 0B-11

Recommended Fluids and Lubricants

Engine oil (Z10XEP / Z12XEP engines)

Engine oil (Z13DT engine)

Engine coolant (Non silicate base coolant) Brake fluid DOT 4 or SAE J1704 Manual transaxle oil (Z10XEP engine model) Door hinges Engine oil or water resistance chassis grease Hood latch assembly Engine oil or water resistance chassis grease Key lock cylinder Spray lubricant

Refer to “Engine Oil and Oil Filter Replacement (Z10XEP / Z12XEP engines)” in this section for engine oil grade and viscosity. Refer to “Engine Oil and Oil Filter Replacement (Z13DT engine)” in this section for engine oil grade and viscosity.

“Antifreeze/Anticorrosion coolant”

Refer to “Manual transaxle Oil Change” in Section 7A4 (Z10XEP engine model).

0B-12 MAINTENANCE AND LUBRICATION

SECTION 1A

HEATER AND VENTILATION 1A-1

HEATER AND VENTILATION

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 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 or 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).

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.

• The link mechanism of the heater varies depending on the specifications.

1A

1B

3 3A 3B

3B1

3C 3D 3E 3F

4A 4B

5 5A 5B 5C 5E

General Description ........................................1A-2

Major Components and Location ..................1A-2

Wiring Circuit.................................................1A-3

On-Board Diagnostic System

(Z13DT Engine Model)..................................1A-3

Diagnosis.........................................................1A-4

Diagnosis Table ............................................1A-4

Diagnostic Trouble Code (DTC) Check

(Z13DT Engine Model)..................................1A-4

Diagnostic Trouble Code (DTC) Table

(Z13DT Engine Model)..................................1A-4

On-Vehicle Service..........................................1A-5

Heater Unit ....................................................1A-5

CONTENTS

Heater Unit Removal and Installation ........... 1A-6

Supplementary Heater (If Equipped)

(Z13DT Engine) ............................................ 1A-6

Supplementary Heater Controller

(If Equipped) (Z13DT Engine) ....................... 1A-6

Supplementary Heater Relay

(If Equipped) (Z13DT Engine) ....................... 1A-7

Blower Motor.................................................1A-7

Blower Motor Resister...................................1A-7

Heater Control Lever Assembly ....................1A-7

Blower Fan and Defogger Switch ................. 1A-7

Air Inlet Box...................................................1A-8

Air Filter Element (If Equipped)..................... 1A-8

1A-2 HEATER AND VENTILATION

General Description

Major Components and Location

HEATER AND VENTILATION 1A-3

1. Heater unit 8. Front defroster air 15. Heater core

2. Air inlet box 9. Side defroster air 16. Temperature control door

3. Ventilator duct 10. Fresh air 17. Foot air control door

4. Defroster nozzle 11. Recirculation air 18. Ventilation defroster air control door

5. Ventilator outlet 12. Center ventilation air 19. Side ventilation control door

6. Side ventilation air 13. Air inlet select door 20. Supplementary heater (if equipped)

7. Foot air 14. Blower motor 21. Supplementary heater controller (if equipped)

Wiring Circuit

Z10XEP, Z12XEP Engine Models

BLU/YEL

BLK/YEL

WHT

BLU/BLK

3

2

RED

1

4

5

6

PNK/BLU

BLK/WHT

7

1. Battery 6. Blower fan motor resister 11. Blower fan motor relay

2. Main fuse box 7. A/C control panel 12. Rear defogger

3. Ignition switch 8. Rear defogger relay 13. ECM

4. Blower fan motor 9. Radiator fan relay

5. To lighting switch 10. Radiator fan motor

RED/WHT

RED

BLU/YEL

8

BRN

PNK

9

BLK/RED

BLK/YEL

PNK

BLK

BLU

BLK/RED

10

11

12

BLK/WHT

GRN/ORN

G21-40

13

G21-14

Z13DT Engine Model

Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

On-Board Diagnostic System (Z13DT Engine Model)

Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

1A-4 HEATER AND VENTILATION

Diagnosis Table

Condition Possible Cause Correction

Heater blower doesn’t work even when its switch is ON.

Incorrect temperature output

When mode control lever is changed, air outlet port is not changed or lever position disagree with air outlet port. Insufficient velocity of air

Diagnosis

• Blower fuse blown Check for short to ground and replace fuse.

• Blower resistor faulty Check resistor.

• Blower switch faulty Check blower switch.

• Blower motor faulty Replace motor.

• Wiring or grounding faulty Repair as necessary.

• Control cables broken or binding Check cables.

• Temperature control lever faulty Check control lever.

• Control cable clamp position faulty Check and adjustment.

• Air damper broken Repair damper.

• Air ducts clogged Repair air ducts.

• Heater radiator leaking or clogged Replace radiator.

• Heater hoses leaking or clogged Replace hoses.

• Thermostat faulty Check thermostat.

• Supplementary heater fuse blown Check supplementary heater fuses.

• Supplementary heater faulty Check supplementary heater (if equipped).

• Supplementary heater controller faulty Check supplementary heater controller (if equipped).

• Supplementary heater relay faulty Check supplementary heater relay (if equipped).

• Water temperature sensor faulty Check water temperature sensor (if equipped).

• Max hot switch faulty Check max hot switch (if equipped).

• Control cables broken or binding Check cable.

• Air damper broken Check control lever.

• Air ducts clogged Check and adjustment.

• Air damper broken Repair damper.

• Air ducts leaking or clogged Repair air ducts.

• Air filter element clogged Check air filter element (if equipped).

Diagnostic Trouble Code (DTC) Check (Z13DT Engine Model)

Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Diagnostic Trouble Code (DTC) Table (Z13DT Engine Model)

Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Heater Unit

HEATER AND VENTILATION 1A-5

On-Vehicle Service

11

8

2

3

6

10

1. Heater core 5. Mode door assembly 9. Supplementary heater (if equipped)

2. Blower motor assembly 6. Air flow control lever 10. Full hot switch (if equipped)

3. Blower motor resistor 7. Temperature control lever 11. Water temperature sensor (if equipped)

4. Temperature control door assembly 8. Heater case

1

5

4

9

1A-6 HEATER AND VENTILATION

Heater Unit Removal and Installation

Removal

1) Disconnect negative (–) cable at battery.

2) If equipped with air bag system, disable air bag system referring to “Disabling Air Bag System” in Section 10B.

3) Drain engine coolant and disconnect heater hoses (1) from heater unit.

4) Remove instrument panel referring to “Instrument Panel” in Section 9.

5) Remove 20-pin connector from supplementary heater controller and two connectors located on supplementary heater controller. (if equipped)

6) Loosen air inlet box (cooling unit) mounting nut (2), and remove mounting nut (3).

7) Remove bolts (4), nuts (5) and screws (6).

8) Remove heater unit (7).

Installation

Install heater unit by reversing removal procedure noting the following items.

• When installing each part, be careful not to catch any cable or wiring harness.

• Adjust heater control cable referring to “Heater Control Lever Assembly” in this section.

• Fill engine coolant to radiator.

• If equipped with air bag system, enable air bag system referring to “Enabling Air Bag System” in Section 10B.

Supplementary Heater (If Equipped) (Z13DT Engine)

Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Supplementary Heater Controller (If Equipped) (Z13DT Engine)

Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

HEATER AND VENTILATION 1A-7

Supplementary Heater Relay (If Equipped) (Z13DT Engine)

Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Blower Motor

The servicing is the same as M13 engine model. Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Blower Motor Resister

The servicing is the same as M13 engine model. Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Heater Control Lever Assembly

The servicing is the same as M13 engine model. Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Blower Fan and Defogger Switch

The servicing is the same as M13 engine model. Refer to same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

1A-8 HEATER AND VENTILATION

Air Inlet Box

2

8

6

5

2

4

1

7

3

2

1. Dash packing 4. Door link 7. Air resistance board

2. Packin g 5. Air inlet door 8. Supplementary heater controller (if equipped)

3. Air filter (if equipped) 6. Air inlet box

6

Removal and Installation

Refer to “Cooling Unit (Evaporator)” in Section 1B.

Air Filter Element (If Equipped)

Removal and Installation

Refer to “Air Filter Element” in Section 1B.

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 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.

• 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

General Description ........................................1B-3

Refrigerant Type Construction ......................1B-3

Air Conditioning System Description.............1B-3

Major Components and Location ..................1B-4

Wiring Circuit.................................................1B-5

Diagnosis.........................................................1B-6

General Diagnosis Table...............................1B-6

Diagnosis Test ..............................................1B-7

Recovery, Evacuation and Charging.............1B-8

Operation Procedure for Charging A/C

with Refrigerant .............................................1B-8

Refrigerant Recovery ....................................1B-9

Evacuating and Charging.............................. 1B-9

Replenishing compressor oil .....................1B-9

When charging refrigerant only ...............1B-10

When replacing compressor ................... 1B-10

On-Vehicle Service .......................................1B-11

Procedure after ECM Replacement ............ 1B-11

A/C Condenser Assembly........................... 1B-12

Receiver / Dryer .......................................... 1B-13

Cooling Unit (Evaporator) ...........................1B-15

Expansion Valve ......................................... 1B-17

Dual Pressure Switch (Z10XEP and

Z12XEP Engine Models)............................. 1B-17

Dual Pressure Switch (Z10XEP and

Z12XEP Engine Models)............................. 1B-18

Pressure Sensor (Z13DT Engine Model) .... 1B-18

A/C Relay.................................................... 1B-19

A/C Compressor Relay ...............................1B-19

Radiator (and Condenser) Cooling Fan

Motor........................................................... 1B-20

1B-2 AIR CONDITIONING (OPTIONAL)

Radiator (and Condenser) Cooling Fan

Relays ......................................................... 1B-21

Air Filter Element ........................................ 1B-21

Compressor Drive Belt................................ 1B-22

Compressor ................................................1B-23

Magnet Clutch............................................. 1B-24

Relief Valve................................................. 1B-25

Compressor Control Valve.......................... 1B-25

Tightening Torque Specifications............... 1B-26

Required Service Material............................ 1B-26

Special Tools ................................................ 1B-26

General Description

Refrigerant Type Construction

Whether the A/C in the vehicle being serviced uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on label (1) on the compressor. Also, it can be checked by the shape of the service (charge) valve (2).

AIR CONDITIONING (OPTIONAL) 1B-3

Air Conditioning System Description

[A]: Liquid 2. Magnet clutch 6. Expansion valve

[B]: Vapor 3. Condenser 7. Evaporator

[C]: Superheated vapor 4. Receiver / dryer

1. Compressor 5. Dual pressure switch (Z10XEP and Z12XEP engine models) Pressure sensor (Z13DT engine model)

1B-4 AIR CONDITIONING (OPTIONAL)

Major Components and Location

[A]: Vehicle with gasoline engine 6. Suction hose 13. Side defroster air

[B]: Vehicle with diesel engine 7. Liquid pipe 14. Fresh air

1. Cooling unit 8. Expansion valve 15. Recirculation air

2. Compressor 9. Side ventilation air 16. Evaporator

3. Condenser assembly 10. Center ventilation air 17. Supplementary heater (if equipped)

4. Receiver / dryer 11. Foot air 18. Blower fan motor

5. Discharge hose 12. Front defroster air

Wiring Circuit

Z10XEP and Z12XEP Engine Models

BLU/YEL

BLK/YEL

WHT

BLU/BLK

3

AIR CONDITIONING (OPTIONAL) 1B-5

BLU/WHT

BLK/WHT

2

BLU/YEL

1

7

4

RED

5

BLK/WHT

RED

RED/WHT

6

PNK/BLU

PNK

8

BRN

9

BLK/RED

BLK/YEL

PNK

BLK

BLU

BLK/RED

10

11

12

16

13

BLK/WHT

ORN

GRN/ORN

G21-40

BLK/YEL

BLK/WHT

15

G21-14

14

G21-30

G21

G21-39

G21-5

-53

17

1. Battery 7. A/C control panel 13. Compressor relay

2. Main fuse box 8. Rear defogger relay 14. Compressor

3. Ignition switch 9. Radiator fan relay 15. A/C switch

4. Blower fan motor 10. Radiator fan motor 16. ECM

5. To lighting switch 11. Blower fan motor relay 17. Dual pressure switch

6. Blower fan motor resister 12. Rear defogger 18. Water temperature sensor

18

C36-42

C36-38

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

ECM and Supplementary Heater Controller Terminal Arrangements for Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

1B-6 AIR CONDITIONING (OPTIONAL)

General Diagnosis Table

Condition Possible Cause Correction Cool air does not come out (A/C system improper operative)

When the blower fan switch is OFF position, blower motor does not operate at A/ C switch is ON

A/C system inoperative

• No refrigerant Recover, evacuation and charging.

• Fuse blown Check fuses and check for short circuit to

• A/C switch faulty Check A/C switch.

• Blower fan switch faulty Check blower fan switch.

• A/C thermistor faulty Check A/C thermistor.

• Dual pressure switch faulty Check dual pressure switch (if equipped).

• Pressure sensor faulty Check pressure sensor (if equipped).

• Wiring or grounding faulty Repair as necessary.

• ECT sensor faulty Check ECT sensor.

• ECM faulty Check ECM.

Compressor inoperative (dose not rotate)

• Fuse blown Check fuse and check for short circuit to

• Compressor relay faulty Check compressor relay.

• Magnet clutch faulty Check magnet clutch.

• Drive belt loose or broken Adjust or replace drive belt.

• Compressor faulty Check compressor.

• ECM faulty Check ECM.

Radiator (and condenser), cooling fan motor inoperative

• Fuse blown Check fuse and check short circuit to

• Radiator cooling fan relay faulty Check radiator cooling fan relay.

• Wiring or grounding faulty Repair as necessary.

• Radiator cooling fan motor faulty Check radiator cooling fan motor.

• ECM faulty Check ECM.

Blower motor inoperative

• Fuse blown Check fuse and check for short circuit to

• Blower resistor faulty Check blower motor resistor.

• Blower fan switch faulty Check blower fan switch.

• Wiring or grounding faulty Repair as necessary.

• Blower motor faulty Check blower motor.

• A/C blower motor relay faulty Check A/C blower motor relay.

• Wiring or grounding faulty Repair as necessary.

• A/C switch faulty Check A/C switch.

Diagnosis

ground.

Condition Possible Cause Correction Cool air does not come out or insufficient cooling (A/C system normal operative)

Cool air does not comes out only intermittently

Cool air comes out only at high speeds

Cool air does not come out only at high speeds Insufficient velocity of cooled air

AIR CONDITIONING (OPTIONAL) 1B-7

• Insufficient or excessive charge of refrigerant

• Condenser clogged Check condenser.

• Evaporator clogged or frosted Check evaporator and position of A/C ther-

• Expansion valve faulty Check expansion valve.

• Receiver / dryer clogged Check receiver / dryer.

• Drive belt slipping Check or replace drive belt.

• Magnetic clutch faulty Check magnetic clutch.

• Compressor faulty Check compressor.

• Air in A/C system Replace receiver / dryer, and evacuation

• Air leaking from cooling unit or air duct

• Heater and ventilation system faulty Check air inlet box assembly.

• Blower motor faulty Check blower motor.

• Excessive compressor oil existing in A/C system

• Wiring connection faulty Repair as necessary.

• Expansion valve faulty Check expansion valve.

• Excessive moisture in A/C system Replace receiver / dryer, and evacuation

• Magnetic clutch faulty Check magnetic clutch.

• Excessive charge of refrigerant Check charge of refrigerant.

• Condenser clogged Check condenser.

• Insufficient charge of refrigerant Check charge of refrigerant.

• Air in A/C system Replace receiver / dryer, and evacuation

• Drive belt slipping Check or replace drive belt.

• Compressor faulty Check compressor.

• Excessive charge of refrigerant Check charge refrigerant.

• Evaporator frosted Check evaporator.

• Evaporator clogged or frosted Check evaporator.

• Air leaking from cooling unit or air duct

• Blower motor faulty Check blower motor.

• Wiring or grounding faulty Repair as necessary.

• Air filter element clogged Check air filter element.

Check charge of refrigerant. Check system for leaks.

mistor.

and charging. Repair as necessary.

Check heater control lever assembly. Check heater assembly.

Pull out compressor oil in A/C system circuit, and replace compressor.

and charging.

Repair as necessary.

Diagnosis Test

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

1B-8 AIR CONDITIONING (OPTIONAL)

Recovery, Evacuation and Charging

Operation Procedure for Charging A/C with Refrigerant

WARNING:

• Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately –6 °C (21 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a serious injury. To protect your eyes against such accident, it is necessary to always wear goggles. Should it occur that HFC-134a (R-134a) strikes your eyes, consult a doctor immediately. – Do not use your hand to rub the affected eye(s). Instead, use quantities of fresh cold water to

splash it over the affected area to gradually raise temperature of such area above freezing point.

– Obtain proper treatment as soon as possible from a doctor or eye specialist.

• Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected are a should be treated in the same manner as when skin is frostbitten or frozen.

• Refrigerant must not be handled near where welding or steam cleaning is performed.

• Refrigerant should be kept at a cold and dark place. It should never be stored where a high temperature is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including trunk room).

• Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazardous to health.

AIR CONDITIONING (OPTIONAL) 1B-9

Refrigerant Recovery

When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment. Discharging it into atmosphere would cause adverse effect to environments.

NOTE:

When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.

Evacuating and Charging

CAUTION:

Because the sight glass is not used for this A/C system, do not perform an additional charge to the A/C system. To charge the proper amount of refrigerant, recover and evacuate the A/C system first. And then, charge the proper amount of refrigerant into the A/C system.

Refer to AIR CONDITIONING BASIC MANUAL (99520-02130).

Z10XEP and Z12XEP Engine Models Specified amount of refrigerant: 500 g

Z13DT Engine Model Specified amount of refrigerant: 480 ± 30 g

[A]: Vehicle with gasoline engine

[B]: Vehicle with diesel engine

1. Manifold gauge set

2. Low pressure gauge

3. High pressure gauge

4. Recovery equipment

5. High pressure service valve

6. Low pressure service valve

Replenishing compressor oil

Z10XEP and Z12XEP Engine Models

It is necessary to replenish specified amount of compressor oil to compressor (1) from compressor suction side hole (2) before evacuating and charging refrigerant.

1B-10 AIR CONDITIONING (OPTIONAL)

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

When charging refrigerant only

Z10XEP and Z12XEP Engine Models

When evacuating and charging refrigerant without replacing any component part, replenish the same amount of measured oil when recovering refrigerant (if not measured, replenish 30 cc oil).

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

When replacing compressor

Z10XEP and Z12XEP Engine Models

CAUTION:

Be sure to use P/N: 99000-990C5-00A compressor oil or an equivalent compressor oil.

Compressor oil is sealed in each new compressor by the amount required for A/C system. Therefore, when using a new compressor for replacement, drain oil from it by the amount calculated as follows.

“C” = “A” – “B” “C”: Amount of oil to be drained “A”: Amount of oil sealed in a new compressor “B”: Amount of oil remaining in removed compressor

NOTE:

Compressor assembly supplied from factory is filled up with the following amount of oil.

Oil amount in compressor

150 cm

3

(150 cc, 9.2 in3)

1. New compressor

2. Removed compressor

3. Compressor oil drain bolt

Tightening torque Compressor oil drain bolt (a): 18 N·m (1.8 kg-m, 13.0 lb-ft)

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

AIR CONDITIONING (OPTIONAL) 1B-11

On-Vehicle Service

NOTE:

When refrigerant line must be disconnected and connected to remove and reinstall any component of A/C system, be sure to observe the following instructions.

• When disconnecting any line from the system, install a blinding plug or cap to fitting of such line immediately.

• When connecting hoses and pipes to each other respectively, previously apply a few drops of compressor oil (refrigerating oil) to O-ring.

• Do not reuse of O-ring.

Z10XEP and Z12XEP Engine Models

1. Suction hose 3. Liquid pipe 5. Receiver / Dryer

2. Discharge hose 4. Expansion valve Apply compressor oil (refrigerant oil) to O-ring.

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Procedure after ECM Replacement

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

1B-12 AIR CONDITIONING (OPTIONAL)

A/C Condenser Assembly

CAUTION:

Be careful not to damage condenser fins. If condenser fin is bent, straighten it by using flat head screwdriver or pair of pliers.

Removal

Z10XEP and Z12XEP Engine Models

1) Disconnect negative (–) cable at battery.

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

3) Remove front bumper referring to “Front Bumper and Rear Bumper” in Section 9.

4) Loosen discharge hose bolt (1) and liquid pipe bolt (2).

5) Loosen condenser mount bolt (3).

6) Remove condenser assembly (4).

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Installation

Z10XEP and Z12XEP Engine Models

Reverse removal sequence to install condenser, noting the following point.

• If replace condenser, pour 15 cc of refrigerating oil to compressor suction-side.

• Evacuate and charge system referring to “Operation Procedure for Charging A/C with Refrigerant” in this section.

Tightening torque Suction hose bolt (a): 10 N·m (1.0 kg-m, 7.5 lb-ft) Discharge hose bolt (b): 10 N·m (1.0 kg-m, 7.5 lb-ft) Condenser mount bolt (c): 5.5 N·m (0.55 kg-m, 4 lb-ft)

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

AIR CONDITIONING (OPTIONAL) 1B-13

Inspection

Z10XEP and Z12XEP Engine Models

Check the following.

• Condenser fins for leakage, blockage and damage

• Condenser fittings for leakage Clogged condenser fins should be washed with water, and should be dried with compressed air.

NOTE:

Be careful not to damage condenser fins. If condenser fin is bent, straighten it by using a screwdriver or pair of pliers. If any leakage is found from fitting or tube, repair or replace condenser.

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Receiver / Dryer

Removal

Z10XEP and Z12XEP Engine Models

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

NOTE:

The amount of removed compressor oil must be measured for replenishing compressor oil.

2) Remove A/C condenser assembly referring to A/C condenser assembly in this section.

3) Loosen receiver / dryer attachment bolt (1), (2).

4) Remove receiver / dryer (3).

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

1B-14 AIR CONDITIONING (OPTIONAL)

Installation

Z10XEP and Z12XEP Engine Models

Reverse removal sequence to install receiver / dryer noting the following points.

• If receiver / dryer (1) is replaced, pour 20 cc of refrigerating oil to compressor suction-side.

• Evacuate and charge system referring to “Operation Procedure for Charging A/C with Refrigerant” in this section.

Tightening torque Receiver / dryer attachment bolt (a): 5.5 N·m (0.55 kg-m, 4 lb-ft)

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Cooling Unit (Evaporator)

AIR CONDITIONING (OPTIONAL) 1B-15

3

4

6

2

3

1

7

4

8

5

4

1. Evaporator 4. Packin g 7. Supplementary heater controller (if equipped)

2. Expansion valve 5. Air filter element 8. Evaporator thermistor (if equipped)

3. Evaporator case 6. Air inlet door

Removal

1) Disconnect negative (–) cable at battery.

2) If equipped with air bag system, disable air bag system referring to “Disabling Air Bag System” in Section 10B.

3) Recover refrigerant from refrigeration system by using recovery and recycling equipment referring to “Operation Procedure for Charging A/C with Refrigerant” in this section.

4) Remove heater control cable, main harness clamp.

5) Remove 20-pin connector from supplementary heater controller and two connectors located on supplementary heater controller (if equipped).

6) Remove evaporator thermistor connector (if equipped).

1B-16 AIR CONDITIONING (OPTIONAL)

7) Loosen suction hose & liquid pipe bolt (4).

8) Loosen cooling unit bolt (1), nut (2) and screw (3) as shown in figure.

9) Remove cooling unit (5).

Installation

Reverse removal sequence to install cooling unit, noting the following points.

• If cooling unit or evaporator is replaced, pour 25 cc of refrigerating oil to compressor suction-side.

1

• Install uniformly the padding (1) to installation hole.

• Evacuate and charge system referring to “Operation Procedure for Charging A/C with Refrigerant” in this section.

• Adjust heater control cable, referring to “Heater Control Lever Assembly” in Section 1A.

• Enable air bag system, if equipped.

Tightening torque Liquid pipe mounting bolt (a): 9.0 N·m (0.9 kg-m, 6.5 lb-ft)

(a)

Inspection

Check the following

• Evaporator fins for leakage, blockage and damage.

• Evaporator fitting for leakage.

Clogged evaporator fins should be washed with water, and should be dried with compressor air.

NOTE:

Be careful not to damage evaporator fins. If evaporator fin is bent, straighten it by using a screwdriver or pair of pliers. If any leakage is found from fitting or tube, repair or replace evaporator.

2, (a)

AIR CONDITIONING (OPTIONAL) 1B-17

Expansion Valve

Removal

1) Recover refrigerant from refrigeration system by using recovery and recycling equipment referring to “Operation Procedure for Charging A/C with Refrigerant” in this section.

2) Loosen liquid pipe mounting bolt (1).

3) Loosen expansion attaching bolt (2) and remove expansion valve (3).

3

1

Installation

Reverse removal procedure for installation, noting the following points.

• Apply compressor oil to expansion valve O-ring and connecting hose and pipe O-ring.

• Evacuate and charge system referring to “Operation Procedure for Charging A/C with Refrigerant” in this section.

Tightening torque Expansion attaching bolt (a): 3.0 N·m (0.3 kg-m, 2.5 lb-ft)

Dual Pressure Switch (Z10XEP and Z12XEP Engine Models)

Removal

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

2) Disconnect negative (–) cable at battery.

3) Remove dual pressure switch.

Installation

Reverse removal procedure for installation, noting the following points.

• Apply compressor oil to dual pressure switch O-ring.

• Evacuate and charge system referring to “Operation Procedure for Charging A/C with Refrigerant” in this section.

Tightening torque Dual pressure switch: 11 N·m (1.1 kg-m, 8.0 lb-ft)

1B-18 AIR CONDITIONING (OPTIONAL)

Dual Pressure Switch (Z10XEP and Z12XEP Engine Models)

Inspection

1) Check dual pressure switch (1) for continuity at normal temper-

ature (approx. 25 charge of refrigerant and when A/C system (compressor) is under operation. In each of these cases, switch should show proper continuity.

°C (77 °F)) when A/C system has a proper

Continuity

No continuity

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

A: Approx 200 KPa (2.0 kg/cm2)

CD

B: Approx 3000 KPa (30 kg/cm2) C: Approx 235 KPa (2.35 kg/cm2) D: Approx 2300 KPa (23 kg/cm2)

AB

Pressure

Pressure Sensor (Z13DT Engine Model)

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

AIR CONDITIONING (OPTIONAL) 1B-19

A/C Relay

1) Disconnect negative (–) cable at battery.

2) Remove steering column hole cover.

3) Remove A/C relay (1).

4) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.

5) Connect battery positive (+) terminal to terminal “b” of relay. Connect battery negative ( Check for continuity between terminal “c” and “d”. If there is no continuity when relay is connected to the battery, replace relay.

–) terminal to terminal “a” of relay.

A/C Compressor Relay

1) Disconnect negative cable at battery.

12

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

1B-20 AIR CONDITIONING (OPTIONAL)

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

Radiator (and Condenser) Cooling Fan Motor

Inspection

Check for continuity between each terminal. If there is no continuity, replace radiator (and condenser) cooling fan motor with new one.

Z10XEP and Z12XEP Engine Models

Connect battery (1) to radiator (and condenser) cooling fan motor coupler (2) as shown in figure, then check that the radiator (and condenser) cooling fan motor operates smoothly. If radiator (and condenser) cooling fan motor does not smoothly operates, replace motor.

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

AIR CONDITIONING (OPTIONAL) 1B-21

Radiator (and Condenser) Cooling Fan Relays

Inspection

1) Disconnect negative cable at battery.

2) Remove radiator cooling fan relay (1) (Z10XEP and Z12XEP engine models), radiator low speed relay and radiator high speed relay (2) (Z13DT engine model) from vehicle.

3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay with new one.

4) Connect battery positive (+) terminal to terminal “b” of relay and battery negative (–) terminal to terminal “a” of relay. Check for continuity between terminal “c” and “d”. If there is no continuity when relay is connected to the battery, replace relay.

Air Filter Element

Removal

1) Remove filter cover (1).

2) Pull out air filter element (1).

1B-22 AIR CONDITIONING (OPTIONAL)

Installation

Reverse removal procedure for installation by noting shown direction.

Inspection and Cleaning

• Check of air filter element for dirt. Replace excessively dirty element.

• Blow off dust by compressed air from air outlet side of element.

Compressor Drive Belt

Inspection

Z10XEP and Z12XEP Engine Models

Refer to “Accessory Drive Belt Inspection” in Section 6B4.

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Adjustment

Z10XEP and Z12XEP Engine Models

Refer to “Accessory Drive Belt Removal and Installation” in Section 6B4.

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Replacement

Z10XEP and Z12XEP Engine Models

Refer to “Accessory Drive Belt Removal and Installation” in Section 6B4.

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

AIR CONDITIONING (OPTIONAL) 1B-23

Compressor

Removal

Z10XEP and Z12XEP Engine Models

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 referring to “Front Bumper and Rear Bumper” in Section 9.

5) Disconnect horn connector, and remove horn (1).

6) Remove engine front cover (2).

7) Remove compressor drive belt referring to “Accessory Drive Belt Removal and Installation” in Section 6B4.

8) Disconnect suction and discharge hoses from compressor.

NOTE:

Cap open fittings immediately to keep moisture out of system.

9) Disconnect magnet clutch connector (3) and disengage lead wire clamp.

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

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

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

1B-24 AIR CONDITIONING (OPTIONAL)

Installation

Z10XEP and Z12XEP Engine Models

Reverse removal procedure to install compressor noting the following instructions.

• If compressor is replaced, pour new compressor oil by referring to “Replenishing Compressor Oil” under “Compressor” in this section.

• Evacuate and charge system by referring to “Operation Procedure for Charging A/C with Refrigerant” in this section.

Tightening torque Suction and discharge hoses bolt (a): 25 N·m (2.5 kg-m, 18.0 lb-ft) Compressor mounting bolt (b): 20 N·m (2.0 kg-m, 14.5 lb-ft)

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Magnet Clutch

Inspection

Z10XEP and Z12XEP Engine Models

• Check armature plate and magnet clutch pulley for wear and oil soaked conditions respectively.

• Check magnet clutch pulley bearing for noise, wear and grease leakage.

• Measure magnet clutch coil for resistance at 20 °C (68 °F). If the measured resistance does not remain within above tolerance, replace compressor assembly.

Standard Resistance: approximately 3.7 Ω

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

AIR CONDITIONING (OPTIONAL) 1B-25

Relief Valve

Inspection

Z10XEP and Z12XEP Engine Models

By using special tool, check if there is refrigerant leakage. If there is refrigerant leakage, replace the compressor assembly.

Special tool (A): 09990–86011

Z13DT Engine Model

Refer to the same section of the Service Manual mentioned in the “FOREWORD” of this service manual.

Compressor Control Valve

Inspection

Z10XEP and Z12XEP Engine Models

By using special tool, check if there is refrigerant leakage. If there is refrigerant leakage, replace the compressor assembly.

Special tool (A): 09990–86011

1B-26 AIR CONDITIONING (OPTIONAL)

Tightening Torque Specifications

Fastening part

Suction hose bolt 10 1.0 7.5 Discharge hose bolt 10 1.0 7.5 Condenser mount bolt 5.5 0.55 4 Receiver /dryer attachment bolt 5.5 0.55 4 Expansion attaching bolt 3 0.3 2.5 Liquid pipe mounting bolt 9 0.9 6.5 Dual pressure switch 11 1.1 8 Suction and discharge hoses bolt 25 2.5 18.0 Compressor mounting bolt 20 2.0 14.5 Compressor oil drain bolt 18 1.8 13

N•m kg-m lb-ft

Tightening torque

Required Service Material

Material

Compressor oil (refrigerant oil)

Recommended SUZUKI product

(Part Number)

COMPRESSOR OIL P/No.: 99000-990C5-00A

Use

•O-ring

• Each component

09990-86011 Gas leak detector

Special Tools

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:

Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for all of this section except the following.

• Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft) which is instructed in the same section of the Service Manual mentioned in “FOREWORD” of this manual.

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft)

3A

3A-2 FRONT WHEEL ALIGNMENT

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

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.

– 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.

• Refer to the same section of the Service Manual mensioned in the FOREWORD of this manual for all of this section except the following. – Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft) which

is instructed in the same section of the Service Manual mensioned in “FOREWORD” of this manual.

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft)

3B-2 MANUAL RACK AND PINION

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.

• Refer to the same section of the Service Manual mensioned in the FOREWORD of this manual for all of this section except the following. – Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft) which

is instructed in the same section of the Service Manual mentioned in “FOREWORD” of this manual.

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft)

3D

3D-2 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

• Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for all of this section except the following. – Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft) which

is instructed in the same section of the Service Manual mentioned in “FOREWORD” of this manual.

– Tighten lateral rod nut (body side) to 90 N·m (9.0 kg-m, 65.0 lb-ft) instead of 100 N·m (10.0 kg-m,

72.5 lb-ft) which is instructed in the same section of the Service Manual mensioned in “FOREWORD” of this manual.

.

3E 3F

4

4B

5 5A 5B 5C

6-2

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft) Lateral rod nut (body side): 90 N·m (9.0 kg-m,

65.0 lb-ft)

6A2

6B2

3E-2 REAR SUSPENSION

WHEELS AND TIRES 3F-1

SECTION 3F

WHEELS AND TIRES

NOTE:

• All wheel 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

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

• For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the Service Manual mentioned in “FOREWORD” of this manual.

3F

General Description ........................................ 3F-2

Tires ..............................................................3F-2

Maintenance And Minor Adjustments............3F-*

Wheel Maintenance .......................................3F-*

Tire Rotation...................................................3F-*

CONTENTS

On-Vehicle Service ......................................... 3F-2

Service Operations ....................................... 3F-2

Wheel Bolts................................................3F-*

Wheel........................................................ 3F-2

Tightening Torque Specifications................. 3F-3

3F-2 WHEELS AND TIRES

General Description

Tires

This vehicle is equipped with the following tire.

Tire specification 155/65R14 75T ········ Z10XEP engine model (petrol) 165/60R14 75T ········ Z12XEP engine model (petrol) 165/60R14 79T ····························· Z13DT engine model (diesel)

The tire is of tubeless type. The tire is designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressures. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration, and unnecessary sharp braking increase tire wear.

On-Vehicle Service

Service Operations

Wheel

Removal

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.

1) Loosen wheel bolts by approximately 180 ° (half a rotation).

2) Hoist vehicle.

3) Make sure that the Vehicle will not fall off by trying to more vehicle body in both ways.

4) Remove wheel bolts except one.

5) Support the wheel and/or tire not to drop the wheel and then remove the bolt left with the wheel.

CAUTION:

Never use heat to loosen tight wheel because application of heat to wheel can shorten life of wheel and damage wheel bearings.

WHEELS AND TIRES 3F-3

Installation

For installation, reverse removal procedure, noting the flowing. Wheel bolts must be tightened in sequence and to proper torque to avoid bending wheel or brake disc, left figure.

NOTE:

Before installing wheels, remove any build-up of corrosion on wheel mounting surface and brake disc mounting surface by scraping and wire brushing. Installing wheels without good metal-to-metal contact at mounting surfaces can cause wheel bolts to loosen, which can later allow a wheel to come off while vehicle is moving.

Tightening order “A” – “B” – “C” – “D”:

Tightening torque

Wheel bolt (a): 110 N·m (11.0 kg-m, 80.0 lb-ft)

Tightening Torque Specifications

Fastening part

Wheel bolt 110 11.0 80.0

N•m kg-m lb-ft

Tightening torque

3F-4 WHEELS AND TIRES

FRONT DRIVE SHAFT (Z10XEP ENGINE MODEL) 4A4-1

SECTION 4A4

FRONT DRIVE SHAFT

(Z10XEP ENGINE MODEL)

NOTE:

• The servicing is the same as G10 engine model. Refer to the same section of the Service Manual mentioned in “FOREWORD” of this manual for all of this section except the following.

• Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft).

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft)

6

6A1

6B

6C 6E1 6F1

6G

6H

6K

7A1 7C1

7D

7F

7D 4A4

8B

8C

8D

8G

9

10

10B

4A4-2 FRONT DRIVE SHAFT (Z10XEP ENGINE MODEL)

FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL) 4A5-1

SECTION 4A5

FRONT DRIVE SHAFT

(Z12XEP ENGINE MODEL)

CONTENTS

General Description ..................................... 4A5-1

Diagnosis...................................................... 4A5-1

On-Vehicle Service....................................... 4A5-2

Front Drive Shaft Assembly Construction .. 4A5-2 Front Drive Shaft Assembly Removal and

Installation .................................................. 4A5-3

Front Drive Shaft Assembly Inspection...... 4A5-4

Front Drive Shaft Components .................. 4A5-5

Front Drive Shaft Disassembly and

Assembly ................................................... 4A5-6

Front Drive Shaft Inspection .................... 4A5-13

Tightening Torque Specification.............. 4A5-13

Special Tools.............................................. 4A5-13

General Description

A constant velocity double offset joint (DOJ) is used on the differential side of the left side drive shaft assembly. A constant velocity tripod joint is used on the differential side of the right side drive shaft assembly. A constant velocity ball joint is used on the wheel side of both the right and left drive shaft assemblies. The drive shaft can slide through the tripod joint or DOJ in the extension/contraction direction.

4A5

Diagnosis

Condition Possible Cause Correction

Abnormal noise Wear or breakage of the drive shaft joint Replace.

4A5-2 FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL)

On-Vehicle Service

Front Drive Shaft Assembly Construction

1. Transaxle 7. Tie-rod end nut 60 N·m (6.0 kg-m, 43.5 lb-ft)

2. Drive shaft assembly 8. Ball stud bolt 175 N·m (17.5 kg-m, 126.5 lb-ft)

3. Tie-rod end 9. Drive shaft nut 110 N·m (11.0 kg-m, 79.5 lb-ft)

4. Suspension control arm 10. Wheel bolt Do not reuse.

5. Stabilizer 11. Drive shaft washer

6. Stabilizer mount bracket bolt 45 N·m (4.5 kg-m, 32.5 lb-ft)

FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL) 4A5-3

Front Drive Shaft Assembly Removal and Installation

Removal

CAUTION:

To prevent the breakage of boots, be careful not to damage the boots when removing drive shaft assembly.

1) Undo caulking (1) and remove drive shaft nut (2).

2) Loosen wheel bolts.

3) Hoist vehicle.

4) Remove wheel.

5) Drain transaxle oil referring to “Manual Transaxle Oil Change” in Section 7A5.

6) Remove tie-rod end nut.

7) Disconnect tie-rod end (1) from steering knuckle (2) by using puller (3).

8) Using tire lever (1), pull out drive shaft joint (2) so as to release snap ring fitting of joint spline at differential side.

9) Remove two stabilizer mount brackets from vehicle body.

1

10) Disconnect front suspension control arm ball joint stud from steering knuckle (1) by pushing down stabilizer bar after removing ball joint bolt (2).

11) Remove drive shaft assembly.

2

4A5-4 FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL)

Installation

CAUTION:

• Be careful not to damage oil seals and boots when installing drive shafts.

• Do not hit boot with hammer. Inserting boot only by hands is allowed.

• Make sure that differential side joint is inserted fully and its snap ring is seated as it was.

Install drive shaft assembly by reversing removal procedure noting the following points.

• Install wheel side joint to steering knuckle first, and then dif-

ferential side joint to transaxle.

• Tighten each bolt and nut to the specified torque referring to

“Front Drive Shaft Assembly Components” in this section.

• Fill transaxle with oil referring to “Manual Transaxle Oil

Change” in Section 7A5.

• Check toe setting and adjust referring to “Toe Setting” and

“Toe Adjustment” in Section 3A.

Front Drive Shaft Assembly Inspection

Inspection

• Check boots for breakage or deterioration.

• Check wheel side joint for rattle or smoothness.

• Check differential side joint for smoothness.

If any abnormality is found, replace.

Front Drive Shaft Components

FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL) 4A5-5

[A]: Right side drive shaft assembly 6. DOJ boot small band 13. DOJ housing

[B]: Left side drive shaft assembly 7. Tripod joint boot 14. Retaining ring

1. Wheel side joint housing (constant velocity ball joint) : Apply black grease included in spare parts.

2. Ball joint boot big band 9. Tripod joint boot big band 16. Snap ring

3. Ball joint boot 10. DOJ boot big band 17. Double offset joint (DOJ)

4. Ball joint boot small band 11. Damper Do not reuse.

5. Tripod joint boot small band 12. Tripod joint

8. DOJ boot 15. Differential side joint housing (Tripod joint)

: Apply brown grease included in spare parts.

: Apply dark brown grease included in spare parts.

4A5-6 FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL)

Front Drive Shaft Disassembly and Assembly

Disassembly

For Tripod joint type (right side)

CAUTION:

• Disassembly of wheel side joint is not allowed. If any abnormality is found, replace it as assembly.

• Do not disassemble tripod joint. If any malcondition is found in it, replace it as differential side joint assembly.

1) Remove differential side boot big band (1) as follows.

For boot big band without joint

a) Remove boot big band by tapping boot and band with plas-

tic hammer. If it is hard to remove boot big band, cut it using a nipper or a iron saw with care not to damage tripod joint housing.

For boot big band with joint

a) Remove boot big band by using flat end rod or the like.

[A]: For boot big band without joint

[B]: For boot big band with joint

2) Take out tripod joint housing (2).

3) Remove grease from shaft, and then take off snap ring (1) by using special tool.

Special tool (A): 09900-06107

4) Remove tripod joint (1) by using 3 arms puller (2).

CAUTION:

To prevent needle bearing of joint from being degreased, do not wash it if it is to be reused.

5) Remove differential side boot small band, and then pull out differential side boot from shaft.

6) Pull out damper through shaft.

FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL) 4A5-7

7) Remove wheel side boot big band (1) as follows.

For boot big band without joint

a) Cut boot big band using a iron saw or a nipper with care not

to damage wheel side joint housing.

For boot big band with joint

a) Remove boot big band by using flat end rod or the like.

8) Remove wheel side boot small band, then pull out wheel side boot from shaft.

[A]: For boot big band without joint

[B]: For boot big band with joint

For DOJ type (left side)

CAUTION:

Disassembly of wheel side joint is not allowed. If any abnormality is found, replace it as assembly.

1) Remove differential side boot big band (1) by using flat end rod or the like.

1

2) Remove DOJ from shaft as follows.

a) Fold over boot and remove old grease so that retaining ring

(1) is accessible.

4A5-8 FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL)

b) Clamp drive shaft in soft jawed vise, and then open retain-

ing ring using special tool and tap DOJ of drive shaft (1) using plastic hammer until retaining ring no longer engages in groove of shaft.

Special tool (A): 09900-06107

c) Remove retaining ring (2) with DOJ (1) from housing (3) if

necessary.

3) Remove differential side boot small band, and then pull out differential side boot from shaft.

4) Pull out damper through shaft.

5) Remove wheel side boot big band (1) as follows.

For boot big band without joint

a) Cut boot big band using a iron saw or a nipper with care not

to damage wheel side joint housing.

For boot big band with joint

a) Remove boot big band by using flat end rod or the like.

6) Remove wheel side boot small band, and then pull out wheel side boot from shaft.

[A]: For boot big band without joint

[B]: For boot big band with joint

FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL) 4A5-9

Assembly

For Tripod joint type (right side)

CAUTION:

Do not wash boot in degreaser, such as gasoline or kerosene, etc. Washing in degreaser causes deterioration of boot.

1) Wash disassembled parts (except boots), and then dry parts completely by blowing air.

2) Clean boots with cloth.

3) Install new wheel side boot on shaft temporarily.

4) Apply grease in the supplied parts to wheel side joint.

Grease color: black Amount: Approximately 70 g (2.47 oz)

5) Fit wheel side boot onto grooves of housing and shaft.

1

6) Place new wheel side boot big band onto boot putting band outer end (1) against forward rotation (2) as shown in figure.

2

7) Confirm that wheel side boot is not stretched or contracted, and then fasten boot big band (1) securely using special tool.

A

Special tool (A): 09943-55010 or 09943-57010

1

4A5-10 FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL)

(A)

1

8) Place new wheel side boot small band (1) onto boot putting band outer end (2) against forward rotation (3) as shown in figure.

9) Confirm that wheel side boot is not stretched or contracted, and then fasten boot small band (1) securely using special tool.

Special tool (A): 09943-55010 or 09943-57010

10) Install damper (1) on right side drive shaft according to dimension specified below.

Length “a”: 347 – 353 mm (13.66 – 13.89 in.)

11) Set new differential side boot small band and differential side boot (1) on shaft temporarily.

12) Install tripod joint (2) on shaft by using special tool with hammer, facing its chamfered spline inward (wheel side), then fasten it with snap ring (3).

Special tool (A): 09900-06107 (B): 09925-98221

13) Apply grease to tripod joint and inside of housing then install housing. Use grease supplied with spare parts.

Grease color: dark brown Amount: Approximately 120 g (4.23 oz)

FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL) 4A5-11

14) Fit boot to grooves of shaft and housing and adjust boot length to specification below. Insert screwdriver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.

Length “a”: Approximately 85.5 mm (3.37 in.)

CAUTION:

• To prevent any problem caused by washing solution, do not wash boot and tripod joint except its housing. Degreasing of those parts with cloth is allowed.

• Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.

[A]: Differential side

15) Install and fasten new boot big and small bands at that position of step 14) in the same procedure as previous steps 6) to 9).

For DOJ type (left side)

1) Install new wheel side boot on shaft according to step 3) to

9) for Tripod joint Type Drive Shaft Assembly.

2) Install damper (1) on drive shaft according to dimension specified below.

Length “a”: 134 – 140 mm (5.2 – 5.5 in.)

3) Install retaining ring (2) and DOJ (1) to housing (3) if necessary.

4A5-12 FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL)

1

2

4) Set new differential side boot small band (2) and differential side boot (1) on shaft temporarily.

5) Apply grease in the supplied parts to DOJ and inside of housing.

Grease color: brown Grease amount: Approx. 120 g (4.23 oz)

6) Place DOJ onto spline of drive shaft and drive onto drive shaft by using plastic hammer until retaining ring engages.

7) Fit boot to grooves of shaft and housing and adjust length “a” to specification below. Insert screwdriver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.

Length “a”: Approximately 74.5 mm (2.93 in.)

CAUTION:

• To prevent any problem caused by washing solution, do not wash boot. Degreasing of those parts with cloth is allowed.

• Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.

[A]: Differential side

8) Install and fasten new boot big and small bands at that position of step 7) in the same procedure as steps 6) to 9) of Tripod Joint Type Drive Shaft Assembly.

FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL) 4A5-13

Front Drive Shaft Inspection

Inspection

• Check shaft and joint for damage, wear or bend. Replace them as necessary.

• Check retaining ring and snap ring for breakage or deformation. Replace as necessary.

Tightening Torque Specification

Fastening part

Ball stud bolt 60 6.0 43.5 Tie rod end nut 45 4.5 32.5 Drive shaft nut 175 17.5 126.5 Wheel bolt 110 11.0 79.5 Stabilizer mount bracket bolt 45 4.5 32.5

N•m kg-m lb-ft

Tightening torque

Special Tools

09900-06107 09925-98221 09943-55010 (J-22610) 09943-57010 Snap ring pliers (Open type)

Bearing installer Boot clamp plier Band compressor

4A5-14 FRONT DRIVE SHAFT (Z12XEP ENGINE MODEL)

BRAKES 5-1

SECTION 5

BRAKES

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 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.

– 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.

5

NOTE:

• When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E1 first.

• All brake 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 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

• Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for all of this section except the following. – Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft) which

is instructed in the same section of the Service Manual mentioned in “FOREWORD” of this manual.

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft)

5-2 BRAKES

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-1

SECTION 5A

BRAKES PIPE/HOSE/MASTER CYLINDER

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 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.

– 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.

5A

NOTE:

• All brake 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 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

• Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for all of this section except the following.

• Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft) which is instructed in the same section of the Service Manual mentioned in "FOREWARD" of this Manual.

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft)

5A-2 BRAKES PIPE/HOSE/MASTER CYLINDER

FRONT BRAKE 5B-1

SECTION 5B

FRONT BRAKE

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 brake 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 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

• Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for all of this section except the following. – Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft) which

is instructed in the same section of the Service Manual mentioned in “FOREWORD” of this manual.

5B

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft)

5B-2 FRONT BRAKE

PARKING AND REAR BRAKE 5C-1

SECTION 5C

PARKING AND REAR BRAKE

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 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.

– 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.

NOTE:

• All brake 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 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 all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

• Refer to the same section of the Service Manual mensioned in the FOREWORD of this manual for all of this section except the following. – Tighten wheel bolt to 110 N·m (11.0 kg-m, 79.5 lb-ft) instead of 95 N·m (9.5 kg-m, 69.0 lb-ft) which

is instructed in the same section of the Service Manual mentioned in “FOREWORD” of this manual.

Tightening torque Wheel bolt: 110 N·m (11.0 kg-m, 79.5 lb-ft)

5C

5C-2 PARKING AND REAR BRAKE

ENGINE GENERAL INFORMATION AND DIAGNOSIS (Z10XEP AND Z12XEP ENGINES) 6-4-1

SECTION 6-4

ENGINE GENERAL INFORMATION AND

DIAGNOSIS

(Z10XEP AND Z12XEP ENGINES)

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 “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.

• 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).

6C3

6E3

6B3

6C3

6E3

6G3

6H3

6K3

CONTENTS

General Information.......................................6-4-3

Statement of Cleanliness and Care ............. 6-4-3

General Information on Engine Service .......6-4-3

Precaution on fuel system service............ 6-4-4

Fuel pressure relief procedure .................6-4-4

Fuel leakage check procedure .................6-4-5

Engine Diagnosis...........................................6-4-6

General Description ..................................... 6-4-6

Precaution in Diagnosing Trouble ................ 6-4-7

Diagnostic Trouble Code (DTC) Check........ 6-4-8

Diagnostic Trouble Code (DTC)

Clearance.....................................................6-4-8

A: Diagnostic System Check........................ 6-4-9

B-01: Diagnostic Trouble Code .................. 6-4-11

B-02: Data List ........................................... 6-4-13

B-03: Connect Scan Tool and Establish

Communication ..........................................6-4-22

B-04: Symptom Chart / Customer

Complaint ...................................................6-4-22

B-05: Complaint: Engine Start.................... 6-4-22

B-06: Complaint: Engine Operation ...........6-4-22

B-07: No Matching Customer Complaint.... 6-4-23

B-08: Check: Intake - Air System ............... 6-4-23

B-09: Check: Exhaust System ................... 6-4-24

B-10: Fuel System......................................6-4-24

B-11: Mechanical Function Check ............. 6-4-25

B12: Actuator Test ..................................... 6-4-25

B-13: Additional Functions ......................... 6-4-31

B-14: Programming.................................... 6-4-31

B-15: Control Test...................................... 6-4-32

B-16: Check: Knock Sensor....................... 6-4-34

B-17: Check: Misfire................................... 6-4-35

B-18: Mechanical Function Check

(Twinport)................................................... 6-4-35

B-19: Check: Intermittent Faults ................ 6-4-36

C-01: No Communication between Scan

tool and Control Module............................. 6-4-37

C-02: Control Module Hard- and

Software..................................................... 6-4-45

C-03: Power Supply Circuit........................ 6-4-45

C-04: Crankshaft Sensor Circuit ................ 6-4-52

C-05: Fuel Pump Relay Circuit .................. 6-4-54

C-06: Pedal Position Sensor Circuit........... 6-4-59

C07: Throttle Position Motor Control

Circuit......................................................... 6-4-69

C-08: Mass Air Flow Circuit ....................... 6-4-74

C-09: Engine Coolant Temperature

Sensor Circuit ............................................ 6-4-78

C-10: Intake Air Temperature

Sensor Circuit ............................................ 6-4-80

C-11: Air Conditioning System Information

Switch Circuit ............................................. 6-4-82

C-12: Air Conditioning System Refrigerant

Pressure Sensor ........................................ 6-4-84

6-4

6-4-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (Z10XEP AND Z12XEP ENGINES)

C-13: Camshaft Position Sensor Circuit .... 6-4-87

C-14: Twinport Sensor Circuit.................... 6-4-89

C-15: Twinport Solenoid Valve Circuit ....... 6-4-91

C-16: Fuel - Tank Level Sensor Circuit...... 6-4-93

C-17: Fuel Injector No.1 Circuit.................. 6-4-95

C-18: Fuel Injector No.2 Circuit.................. 6-4-97

C-19: Fuel Injector No.3 Circuit.................. 6-4-99

C-20: Fuel Injector No.4 Circuit................ 6-4-101

C-21: Ignition Coil Cylinder 1 Circuit ........ 6-4-102

C-22: Ignition Coil Cylinder 2 Circuit ........ 6-4-105

C-23: Ignition Coil Cylinder 3 Circuit ........ 6-4-107

C-24: Ignition Coil Cylinder 4 Circuit ........ 6-4-109

C-25: Knock Sensor Signal Circuit........... 6-4-111

C-26: Linear Exhaust Gas Recirculation

System Circuit.......................................... 6-4-113

C-27: EVAP Canister Purge Valve

Circuit....................................................... 6-4-116

C-28: O2 Sensor Heater Circuit

(HO2S-1).................................................. 6-4-118

C-29: O2 Sensor Circuit (HO2S-1) .......... 6-4-120

C-30: O2 Sensor Heater Circuit

(HO2S-2) ..................................................6-4-122

C-31: O2 Sensor Circuit (HO2S-2) ...........6-4-125

C-32: Air Conditioning System

Compressor Circuit ...................................6-4-127

C-33: Fan Circuit.......................................6-4-132

C-34: Brake (Stop) Lamp Switch Circuit ...6-4-136 C-35: Malfunction Indication Lamp

(MIL) Circuit ..............................................6-4-141

C-36: Service Vehicle Soon (SVS) Lamp

Circuit........................................................6-4-143

C-37: System Status Information..............6-4-145

C-38: Engine - Compression ....................6-4-145

C-39: Catalyst System ..............................6-4-145

C-40: Control Module Hard- and

Software 1.................................................6-4-146

C-41: Ignition Status Circuit ......................6-4-146

Special Tool ................................................6-4-146

ENGINE GENERAL INFORMATION AND DIAGNOSIS (Z10XEP AND Z12XEP ENGINES) 6-4-3

51General Information

Statement of Cleanliness and Care

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousands of an millimeter (ten thousands of inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.

• A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surface on initial operation.

• Whenever valve train components, pistons, piston rings, connecting rods, rod bearings and crankshaft journal bearings are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

• Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.

• Throughout this manual, the three or four cylinders of the engine are identified by numbers: No.1, No.2, No.3 and No.4 as counted from crankshaft pulley side (1) to flywheel side.

General Information on Engine Service

The following information on engine service should be noted carefully, as it is important in preventing damage, and in contributing to reliable engine performance.

• When raising or supporting engine for any reason, do not use a jack under oil pan. Due to small clearance between oil pan and oil pump strainer, jacking against oil pan may cause it to be bent against strainer resulting in damaged oil pick-up unit.

• It should be kept in mind, while working on engine, that 12volt electrical system is capable of violent and damaging short circuits. When performing any work where electrical terminals could possibly be grounded, ground cable of the battery should be disconnected at battery.

• Any time the air cleaner, air cleaner outlet hose, or intake manifold is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material which could follow intake passage into cylinder and cause extensive damage when engine is started.

6-4-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (Z10XEP AND Z12XEP ENGINES)

Precaution on fuel system service

• Work must be done with no smoking, in a well-ventilated area and away from any open flames.

• A small amount of fuel may be released after fuel line is disconnected. In order to reduce the chance of personal injury, cover fitting to be disconnected with a shop cloth. Put that cloth in an approved container when disconnection is completed.

• Never run engine with main relay disconnected when engine and exhaust system are hot.

• Fuel or fuel vapor hose connection varies with each type of pipe. When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to the figure. After connecting, make sure that it has no twist or kink.

[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.

[B]: With following type pipe, fit hose as far as its peripheral projection as shown.

[C]: With bent pipe, fit hose as its bent part as shown or till pipe is about 20 to 30 mm

(0.79 – 1.18 in.) into the hose.

[D]: With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79 – 1.18 in.) into the hose.

1. Hose

2. Pipe

3. Clamp

4. Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.

5. 20 to 30 mm (0.79 – 1.18 in.)

• When installing injector, fuel feed pipe or fuel pressure regulator, lubricate its O-ring with spindle oil or fuel.

• When connecting fuel pipe flare nut, first tighten flare nut by hand and then tighten it to specified torque, using back-up wrench.

Fuel pressure relief procedure

CAUTION:

This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.

NOTE:

If any service shown below is performed, ECM may detect DTC(s). Therefore, clear DTC(s) by referring to “DTC Clearance” in this section in case that DTC(s) is detected after all services are done.

After making sure that engine is cold, release fuel pressure as follows.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (Z10XEP AND Z12XEP ENGINES) 6-4-5

1) Place transmission gear shift lever in “Neutral”, set parking brake, and block drive wheels.

2) Remove relay box cover.

2

3) Disconnect fuel pump relay (1) from relay box (2).

4) Remove fuel filter cap to release fuel vapor pressure in fuel tank and then reinstall it.

1

5) Start engine and run it till it stops for lack of fuel. Repeat cranking engine 2-3 times for about 3 seconds each time to dissipate fuel pressure in lines. Fuel connections are now safe for servicing.

6) Upon completion of servicing, connect fuel pump relay (1) to relay box (2) and install relay box cover.

Fuel leakage check procedure

After performing any service on fuel system, check to make sure that there are no fuel leakages as follows.

1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF. Repeat this (ON and OFF) 3 or 4 times and apply fuel pressure to fuel line (till fuel pressure is felt by hand placed on fuel feed hose).

2) In this state, check to see that there are no fuel leakages from any part of fuel system.

Suzuki Wagon R+ RB310 RB412 RB413D Service Manual 99501U83E50-01E

Specifications and Main Features

Frequently Asked Questions

User Manual

IMPORTANT

WARNING/CAUTION/NOTE

Table of Contents

SECTION 0A

Identification Information

Vehicle Identification Number

Engine Identification Number

Transmission Identification Number

Warning, Caution and Information Labels

Abbreviations and Symbols May be Used in This Manual

Abbreviations

SECTION 0B

Maintenance Schedule

Maintenance Schedule Under Normal Driving Conditions

Maintenance Recommended Under Severe Driving Conditions

Maintenance Service

Engine Accessory Drive Belt Inspection (Z10XEP / Z12XEP Engines)

Engine Accessory Drive Belt Replacement (Z10XEP / Z12XEP Engines)

Engine Oil and Oil Filter Replacement (Z10XEP / Z12XEP Engines)

Engine Coolant Replacement

Spark Plugs Replacement

Air Cleaner Filter Inspection (Z10XEP / Z12XEP Engines)

Air Cleaner Filter Replacement (Z10XEP / Z12XEP Engines)

Clutch Inspection

Manual Transaxle Oil Inspection (Z10XEP Engine Model)

Manual Transaxle Oil Replacement (Z10XEP Engine Model)

Recommended Fluids and Lubricants

SECTION 1A

General Description

Major Components and Location

Wiring Circuit

On-Board Diagnostic System (Z13DT Engine Model)

Diagnosis Table

Diagnosis

Diagnostic Trouble Code (DTC) Check (Z13DT Engine Model)

Diagnostic Trouble Code (DTC) Table (Z13DT Engine Model)

Heater Unit

On-Vehicle Service

Heater Unit Removal and Installation

Supplementary Heater (If Equipped) (Z13DT Engine)

Supplementary Heater Controller (If Equipped) (Z13DT Engine)

Supplementary Heater Relay (If Equipped) (Z13DT Engine)

Blower Motor

Blower Motor Resister

Heater Control Lever Assembly

Blower Fan and Defogger Switch

Air Inlet Box

Air Filter Element (If Equipped)

SECTION 1B

General Description

Refrigerant Type Construction

Air Conditioning System Description

Major Components and Location

Wiring Circuit

General Diagnosis Table

Diagnosis

Diagnosis Test

Recovery, Evacuation and Charging

Operation Procedure for Charging A/C with Refrigerant

Refrigerant Recovery

Evacuating and Charging

Replenishing compressor oil

When charging refrigerant only

When replacing compressor

On-Vehicle Service

Procedure after ECM Replacement

A/C Condenser Assembly

Receiver / Dryer

Cooling Unit (Evaporator)

Expansion Valve

Dual Pressure Switch (Z10XEP and Z12XEP Engine Models)

Dual Pressure Switch (Z10XEP and Z12XEP Engine Models)

Pressure Sensor (Z13DT Engine Model)

A/C Relay

A/C Compressor Relay

Radiator (and Condenser) Cooling Fan Motor