99500_60G20_01E_V2.pdf

(11224 KB) Pobierz
<!DOCTYPE html PUBLIC "-//W3C//DTD HTML 4.01//EN" "http://www.w3.org/TR/html4/strict.dtd">
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 mean-
ings. Pay special attention to the messages high-
lighted by these signal words.
WARNING:
For vehicles equipped with Supplemental
Restraint (Air Bag) System:
Service on or around the air bag system
components must be performed only by
an authorized SUZUKI dealer. Please ob-
serve all WARNINGS, CAUTIONS and
“Service Precautions” under “On-Vehicle
Service” in SECTION 10B before perform-
ing service on or around the air bag sys-
tem components or wiring. Failure to
follow WARNINGS could result in uninten-
tional activation of the system or could
render the system inoperative. Either of
these two conditions may result in severe
injury.
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 mainte-
nance easier or instructions clearer.
If the air bag system and another vehicle
system both need repair, SUZUKI recom-
mends that the air bag system be repaired
first, to help avoid unintentional activa-
tion of the air bag system.
Do not modify the steering wheel, instru-
ment panel or any other air bag system
component. Modifications can adversely
affect air bag system performance and
lead to injury.
If the vehicle will be exposed to tempera-
tures over 93
WARNING:
This service manual is intended for autho-
rized SUZUKI dealers and qualified service
mechanics only. Inexperienced mechanics
or mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle un-
safe for the driver and passengers.
F) (for example, dur-
ing a paint baking process), remove the
air bag system components (air bag (infla-
tor) modules, SDM and seat belt preten-
sioner (if equipped)) beforehand to avoid
component damage or unintended activa-
tion of the system.
C (200
882671597.017.png
FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service op-
erations, replacement of components (Service) and for disassembly and assembly of major components (Unit Re-
pair-Overhaul).
VOLUME 1 contains Chassis, Electrical and Body sections (all sections except engine).
VOLUME 2 contains Engine sections (Section 6 – 6K).
Applicable model: SY413/SY416/SY418 on and after the following VIN NO.
HATCHBACK
GA11S-200001
JSAEGA11S00200001
JSAEGA41S00200001
x
x
x
x
JSAEGA31S00200001
JSAEGB31S00200001
x
x
x
x
SEDAN
GC11S-200001
JS2GB31S
15200001
JSAEGC31S15200001
x
x
GC31S-200001
JS2GB41S
15200001
JSAEGC41S00200001
x
x
JS2GA11S
15200001
JSAEGC11S00200001
JSAEGD31S00200001
x
x
x
x
JS2GA31S
15200001
JSAEGC31S00200001
x
x
JS2GA41S
15200001
JSAEGC31S10200001
x
x
WAGON
GC31W-200001
JS2GB31W
15200001
JSAEGC31W10200001
x
x
GC41W-200001
JS2GB41W
15200001
JSAEGC31W15200001
x
x
JS2GA31W
15200001
JSAEGC11W00200001
JSAEGC41W00200001
x
x
x
x
JS2GA41W
15200001
JSAEGC31W00200001
JSAEGD31W00200001
x
x
x
x
The contents are classified into sections each of which is given a section number as indicated in the Table of Con-
tents on next page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
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 informa-
tion available at the time of publication approval. And used as the main subject of description is the vehicle of stan-
dard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
RELATED MANUAL
SY413/SY416/SY418 Wiring Diagram Manual
(99512-60G60-015)
OVERSEAS SERVICE DEPARTMENT
COPYRIGHT SUZUKI MOTOR CORPORATION 2000
882671597.018.png 882671597.019.png 882671597.020.png 882671597.001.png 882671597.002.png
6
0A
TABLE OF CONTENTS
SECTION
TABLE OF CONTENTS
SECTION
0B
6-1
ENGINE
Engine (G13/G16 Engine without
WU-TWC)
Engine General Information and
Diagnosis
(G13/G16 Engine with WU-TWC)
Engine General Information and
Diagnosis
(J18 Engine with WU-TWC)
Engine Mechanical
(G13 and G16 Type Engine)
Engine Mechanical
(J18 Type Engine)
Engine Cooling
Engine Fuel
Electronic Fuel Injection System
(G13/G16 Engine without
WU-TWC)
Engine and Emission Control
System
(G13/G16 Engine with WU-TWC)
Electronic Fuel Injection System
(J18 Engine without WU-TWC)
Engine and Emission Control Sys-
tem (J18 Engine with WU-TWC)
Ignition System (G13/G16 Engine)
Ignition System (J18 Engine)
Cranking System
(0.8 kW Reduction Type)
Cranking System
(0.8 kW Conventional Type)
Cranking System
(0.9/1.2/1.4 kW Reduction Type)
Charging System
Exhaust System
GENERAL INFORMATION
General Information
Maintenance and Lubrication
0A
6
1A
6-2
0B
6A1
1B
HEATING AND VENTILATION
Heater and Ventilation
Air Conditioning (Optional)
6-1
1A
6A3
3
1B
6-2
3A
6B
STEERING, SUSPENSION,
WHEELS AND TIRES
Steering, Suspension,
Wheels and Tires
Front End Alignment
Manual Rack and Pinion
Power Steering (P/S) System
(Hydraulic Type)
Steering Wheel and Column
(Without Air Bag)
Air Bag Steering and Column
Front Suspension
Rear Suspension (2WD)
Rear Suspension (4WD)
Wheels and Tires
Suspension Control System
3B
6C
6A1
3
3A
6E1
3B1
6A3
6E2
3C
6B
3B
6C
3C1
6E3
3B1
3D
6E4
6E1
3C
6F1
3E
3C1
6E2
3E1
6F2
3D
3E
3F
6G1
3E1
6E3
3F
6G2
3G
6E4
3G
6G3
4
6F1
DRIVE SHAFT
Front Drive Shaft (DOJ Type)
Front Drive Shaft
(Tripod Joint Type)
Propeller Shafts
Rear Drive Shaft
6F2
4
4A
6H
6G1
4A
4B
6K
4B
4C
6G2
7A
4C
6G3
7A1
5
BRAKE SYSTEM
Brakes
Antilock Brake System (ABS)
6H
5
5B
7A2
6K
5B
7B
TRANSMISSION AND CLUTCH
Manual Transmission
(G13 and G16 Engine Models)
Manual Transmission
(J18 Engine Model)
Manual Transmission (4WD)
Automatic Transmission (3 A/T)
Automatic Transmission (4 A/T)
Clutch (Cable Type)
Clutch (Hydraulic Type)
Rear Differential
7B1
7A
7C
7A1
7A2
7C1
7B
7F
7B1
7C
8
7C1
7F
8A
8
BODY ELECTRICAL SYSTEM
WIRING DIAGRAM
IMMOBILIZER CONTROL SYSTEM
BODY SERVICE
AIR BAG SYSTEM
8G
8A
9
8G
9J
9
9J
NOTE:
The screen toned Sections 0A – 5B and 7A – 9J are included in Volume 1 of 2 and Section 8A is in Wiring
Diagram Manual.
882671597.003.png 882671597.004.png
 
882671597.005.png 882671597.006.png 882671597.007.png 882671597.008.png 882671597.009.png 882671597.010.png 882671597.011.png
 
ENGINE (ENGINE WITHOUT WU TWC)
6-1
6
Section 6
ENGINE
WARNING:
For vehicles equipped with Supplement 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” un-
der “General Description” in air bag system section in order to confirm whether you are perform-
ing 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 perform-
ing 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. Ei-
ther 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 sys-
tem may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
According the vehicle specification (engine type and whether WU TWC equipped or not), the reference
section is different.
Confirm the vehicle specification referring to “IDENTIFICATION INFORMATION” in Section 0A and refer
to the applicable section.
Wether the following systems (parts) are used in the particular vehicle or not depends on vehicle specifi-
cations. Be sure to bear this in mind when performing service work.
– EGR valve/heated oxygen sensor or CO adjusting resistor/three-way catalytic converter (TWC)
– Heated oxygen sensor-2 (HO2S-2)/CKP sensor/Warm up three way catalytic converter (WU TWC)
ENGINE (Engine Without WU TWC)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
ENGINE GENERAL INFORMATION AND DIAGNOSIS (G13/G16 Engine With WU TWC)
. . . . . . . . . . . . . . . . .
6-1-1
ENGINE GENERAL INFORMATION AND DIAGNOSIS (J18 Engine With WU TWC)
. . . . . . . . . . . . . . . . . . . . .
6-2-1
ENGINE MECHANICAL (G13/G16 Engine)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A1-1
ENGINE MECHANICAL (J18 Engine)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A3-1
ENGINE COOLING (G13/G16 Engine)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6B-1
ENGINE COOLING (J18 Engine)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6B1-1
ENGINE FUEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6C-1
ELECTRONIC FUEL INJECTION SYSTEM (G13/G16 Engine Without WU TWC)
. . . . . . . . . . . . . . . . . . . . . . .
6E1-1
ENGINE AND EMISSION CONTROL SYSTEM (G13/G16 Engine With WU TWC)
. . . . . . . . . . . . . . . . . . . . . . .
6E2-1
ELECTRONIC FUEL INJECTION SYSTEM (J18 Engine Without WU TWC)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E3-1
ENGINE AND EMISSION CONTROL SYSTEM (J18 Engine With WU TWC)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E4-1
IGNITION SYSTEM (G13/G16 Engine)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6F1-1
IGNITION SYSTEM (J18 Engine)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6F2-1
CRANKING SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6G-1
882671597.012.png 882671597.013.png 882671597.014.png
 
6-2
ENGINE (ENGINE WITHOUT WU TWC)
CHARGING SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6H-1
EXHAUST SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6K-1
CONTENTS
GENERAL INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Statement on cleanliness and care (for G13/G16 engine models)
6- 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6- 3
Statement on cleanliness and care (for J18 engine model)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6- 4
General information on engine service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6- 4
Precaution on fuel system service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6- 6
Fuel pressure relief procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6- 7
Fuel leakage check procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6- 7
ENGINE DIAGNOSIS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine diagnosis flow chart (for G13/G16 engine models)
6- 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6- 8
Engine diagnosis table (for G13/G16 engine models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6- 9
Engine diagnosis flow chart (for J18 engine model)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14
Engine diagnosis table (for J18 engine model)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-19
882671597.015.png 882671597.016.png

Plik z chomika:

Inne pliki z tego folderu:

Inne foldery tego chomika:

Zgłoś jeśli naruszono regulamin