Suzuki Liana RH418 Supplementary Service Manual

IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words

, and NOTE have special meanings. Pay special attention to the messages high-

lighted by these signal words.

The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.

WARNING

!

CAUTION

!

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

WARNING

!

Indicates a potential hazard that could result in vehicle damage.

CAUTION

!

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

This service manual is intended for authorized Suzuki dealers and qualified service technicians only.

Inexperienced technicians or technicians 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 technician 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 ser-

vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-

vice 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, that is air bag (inflator) modules, SDM and/or seat

belt with pretensioner, beforehand to avoid component damage or unintended activation.

WARNING

!

FOREWORD

This SUPPLEMENTARY SERVICE MANUAL is a supplement to LIANA (RH413/RH416) SERVICE MANUAL.

It has been prepared exclusively for the following applicable model.

Applicable model:

LIANA (RH418) vehicles on and after the following vehicle identification numbers (VINs).

This supplementary service manual describes only different service information of the above applicable model

as compared with LIANA (RH413/RH416) SERVICE MANUAL. Therefore, whenever servicing the above appli-

cable models, consult this supplement first. And for any section, item or description not found in this supplement,

refer to the related manual below.

When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and

service materials as specified in each description.

All information, illustrations and specifications contained in this literature are based on the latest product infor-

mation available at the time of publication approval. And used as the main subject of description is the vehicle of

standard specifications among others.

Therefore, note that illustrations may differ from the vehicle being actually serviced.

The right is reserved to make changes at any time without notice.

Related Manuals:

SEDAN:

RC51S-150001 JSAERA51S00200001

WAGON:

RD51S-150001 JSAERC51S00250001

Manual Name Manual No.

LIANA (RH413/RH416) SERVICE MANUAL 99500-54G10-01E

00

0

1

2

3

4

5

6

7

8

9

10

11

Precautions............................................................... 00-*

Precautions ............................................................. 00-*

General Information ................................................... 0-i

General Information ...............................................0A-1

Maintenance and Lubrication ................................. 0B-1

Engine ......................................................................... 1-i

Precautions .............................................................. 1-1

Engine General Information and Diagnosis ...........1A-1

Aux. Emission Control Devices .............................. 1B-1

Engine Electrical Devices.......................................1C-1

Engine Mechanical.................................................1D-1

Engine Lubrication System .................................... 1E-1

Engine Cooling System...........................................1F-*

Fuel System ...........................................................1G-1

Ignition System....................................................... 1H-*

Starting System........................................................ 1I-*

Charging System..................................................... 1J-*

Exhaust System ......................................................1K-*

Suspension................................................................. 2-*

Precautions ............................................................... 2-*

Suspension General Diagnosis...............................2A-*

Front Suspension ....................................................2B-*

Rear Suspension.................................................... 2C-*

Wheels and Tires ................................................... 2D-*

Driveline / Axle ........................................................... 3-i

Drive Shaft / Axle ...................................................3A-1

Brakes ......................................................................... 4-*

Brake Control System and Diagnosis .....................4A-*

Front Brakes............................................................4B-*

Rear Brakes ........................................................... 4C-*

Parking Brake......................................................... 4D-*

ABS .........................................................................4E-*

Transmission / Transaxle .......................................... 5-i

Precautions .............................................................. 5-1

Automatic Transmission/Transaxle ........................5A-1

Manual Transmission/Transaxle ............................ 5B-*

Clutch ..................................................................... 5C-*

Steering.......................................................................6-*

Precautions ...............................................................6-*

Steering General Diagnosis ................................... 6A-*

Steering Wheel and Column .................................. 6B-*

Power Assisted Steering System ........................... 6C-*

HVAC ...........................................................................7-*

Precautions ...............................................................7-*

Heater and Ventilation............................................ 7A-*

Air Conditioning System......................................... 7B-*

Restraint......................................................................8-*

Precautions ...............................................................8-*

Seat Belts............................................................... 8A-*

Air Bag System ...................................................... 8B-*

Body, Cab and Accessories ...................................... 9-i

Precautions ...............................................................9-*

Wiring Systems ...................................................... 9A-*

Lighting Systems.................................................... 9B-*

Instrumentation / Driver Info. / Horn .......................9C-1

Wipers / Washers................................................... 9D-*

Glass / Windows / Mirrors ......................................9E-1

Security and Locks..................................................9F-*

Seats ...................................................................... 9G-*

Interior Trim............................................................ 9H-*

Hood / Fenders / Doors........................................... 9J-*

Body Structure ....................................................... 9K-*

Paint / Coatings.......................................................9L-*

Exterior Trim...........................................................9M-*

Control systems .......................................................10-*

Immobilizer Control System ................................. 10C-*

TABLE OF CONTENTS

NOTE

For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same

sections of the service manual mentioned in the “FOREWORD” of this manual.

Table of Contents 0- i

0

Section 0

CONTENTS

General Information

General Information ................................ 0A-1

General Description .............................................0A-1

Abbreviations .......................................................0A-*

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

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

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

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

Vehicle Identification Number ..............................0A-*

Engine Identification Number ...............................0A-*

Transmission Identification Number....................0A-1

Component Location ........................................... 0A-*

Warning, Caution and Information Labels

Location .............................................................0A-*

Maintenance and Lubrication................. 0B-1

Precautions........................................................... 0B-*

Precautions for Maintenance and Lubrication......0B-*

Scheduled Maintenance ...................................... 0B-*

Normal Condition Schedule .................................0B-*

Maintenance Recommended under Severe

Driving Conditions..............................................0B-*

Repair Instructions ..............................................0B-1

Drive Belt Inspection ............................................0B-*

Drive Belt Replacement .......................................0B-*

Valve Lash (Clearance) Inspection ......................0B-*

Engine Oil and Filter Change ...............................0B-*

Engine Coolant Change .......................................0B-*

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

Spark Plugs Replacement ...................................0B-*

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

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

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

Fuel Filter Replacement.......................................0B-*

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

PCV Valve Inspection ......................................... 0B-*

Fuel Evaporative Emission Control System

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

Tires / Wheels Inspection.................................... 0B-*

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

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

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

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

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

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

Manual Transaxle Oil Inspection......................... 0B-*

Manual Transaxle Oil Replacement .................... 0B-*

Automatic Transaxle Fluid Inspection .................0B-1

Automatic Transaxle Fluid Replacement ............0B-1

Automatic Transaxle Fluid Cooler Hose

Inspection..........................................................0B-1

Transfer Oil (4WD A/T) and Rear Differential

Oil (4WD) Inspection .........................................0B-2

Transfer Oil (4WD A/T) and Rear Differential

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

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

Power Steering (P/S) System Inspection ............ 0B-*

Final Inspection for Maintenance Service ........... 0B-*

Specifications....................................................... 0B-*

Tightening Torque Specifications........................ 0B-*

Special Tools and Equipment ............................. 0B-*

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

Special Tool ........................................................ 0B-*

NOTE

For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual

mentioned in the “FOREWORD” of this manual.

0A-1 General Information:

General Information

General Description

Transmission Identification Number

S3RH0B0101008

The automatic transmission identification number is located on transmission case.

I3RH01010004-01

Maintenance and Lubrication: 0B-1

Maintenance and Lubrication

Repair Instructions

Automatic Transaxle Fluid Inspection

S3RH0B0206030

1) Inspect transaxle case for evidence of fluid leakage.

Repair leaky point, if any.

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

check.

3) Pull out dipstick and check fluid level.

For fluid level checking procedure, refer to “A/T Fluid

Level Check in Section 5A” and be sure to perform it

under specified conditions. If fluid level is low,

replenish specified fluid.

Automatic Transaxle Fluid Replacement

S3RH0B0206031

1) Inspect transaxle case for evidence of fluid leakage.

Repair leaky point, if any.

2) Make sure that vehicle is placed level.

3) Change fluid. For its procedure, refer to “A/T Fluid

Change in Section 5A”.

Automatic Transaxle Fluid Cooler Hose

Inspection

S3RH0B0206032

Check automatic transaxle fluid cooler hose for fluid

leakage, cracks, damage and deterioration.

Replace hose and/or clamp if any faulty condition is

found.

1. Dipstick 3. LOW HOT mark

2. FULL HOT mark

1. Drain plug

I2RH01020030-01

1

I2RH01020031-01

I3RH0B020001-01

0B-2 Maintenance and Lubrication:

Transfer Oil (4WD A/T) and Rear Differential Oil (4WD) Inspection

S3RH0B0206033

1) Check transfer case or differential for evidence of oil leakage.

Repair leaky point if any.

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

3) Remove level plug of transfer or differential and check oil level.

Oil level can be checked roughly by means of level plug hole. That is, if oil flows out of level plug hole or if oil level

is found up to hole when level plug is removed, oil is properly filled.

If oil is found insufficient, pour specified amount of specified oil.

4) Tighten level plug to specified torque.

[A]: Transfer 1. Oil level/filler plug

[B]: Rear differential 2. Drain plug

I2RH0B020014-01

Table of Contents 1- i

1

Section 1

CONTENTS

Engine

Precautions .................................................1-1

Precautions............................................................. 1-1

Precautions for Engine.......................................... 1-1

Engine General Information and

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

Precautions...........................................................1A-1

Precautions on Engine Service ...........................1A-1

Precautions in Diagnosing Trouble ..................... 1A-1

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

Statement on Cleanliness and Care ................... 1A-2

Engine Diagnosis General Description ............... 1A-2

On-Board Diagnostic System Description........... 1A-2

Engine and Emission Control System

Description ........................................................ 1A-3

Air Intake System Description............................. 1A-4

Electronic Control System Description................ 1A-4

Engine and Emission Control Input / Output

Table ................................................................. 1A-9

Schematic and Routing Diagram......................1A-10

Engine and Emission Control System

Diagram ..........................................................1A-10

Component Location .........................................1A-12

Electronic Control System Components

Location ..........................................................1A-12

Diagnostic Information and Procedures..........1A-13

Engine and Emission Control System Check....1A-13

Malfunction Indicator Lamp (MIL) Check .......... 1A-15

DTC Check ....................................................... 1A-15

DTC Clearance ................................................. 1A-16

DTC Table.........................................................1A-17

Fail-Safe Table.................................................. 1A-18

Scan Tool Data ................................................. 1A-19

Visual Inspection ............................................... 1A-23

Engine Basic Inspection.................................... 1A-23

Engine Symptom Diagnosis ..............................1A-27

Malfunction Indicator Lamp Does Not Come

ON at Ignition Switch ON (But Engine at

Stop) ...............................................................1A-36

Malfunction Indicator Lamp Remains ON after

Engine Starts .................................................. 1A-38

MIL Flashes at Ignition Switch ON ....................1A-39

MIL Does Not Flash or Just Remains ON

Even with Grounding Diagnosis Switch

Terminal ..........................................................1A-40

MIL Does Not Light at Ignition Switch ON and

Engine Does Not Start Through It Is Cranked

Up....................................................................1A-41

DTC P0011 (No. 32) / P0012 (No. 32):

Camshaft Position-Timing Over-Advanced

or System Performance / Timing Over-

Retarded .........................................................1A-44

DTC P0105 (No. 11): Manifold Absolute

Pressure (MAP) Circuit Malfunction ................1A-46

DTC P0110 (No. 18): Intake Air Temp. (IAT)

Circuit Malfunction...........................................1A-48

DTC P0115 (No. 19): Engine Coolant Temp.

(ECT) Circuit Malfunction ................................1A-50

DTC P0120 (No. 13): Throttle Position Circuit

Malfunction......................................................1A-52

DTC P0130 (No. 14): Heated Oxygen Sensor

(HO2S) Circuit Malfunction (Sensor-1) ...........1A-54

DTC P0135 (No. 14): Heated Oxygen Sensor

(HO2S) Heater Circuit Malfunction (Sensor-

1) .....................................................................1A-56

DTC P0325 (No. 17): Knock Sensor Circuit

Malfunction......................................................1A-58

DTC P0335 (No. 23): Crankshaft Position

(CKP) Sensor Circuit Malfunction ...................1A-60

DTC P0340 (No. 15): Camshaft Position

(CMP) Sensor Circuit Malfunction...................1A-63

DTC P0500 (No. 16): Vehicle Speed Sensor

(VSS) Malfunction ...........................................1A-66

DTC P0601: Internal Control Module Memory

Check Sum Error.............................................1A-70

DTC P1450 (No.29): Barometric Pressure

Sensor Circuit Malfunction ..............................1A-70

DTC P1915 (No. 33): Oil Control Valve Circuit ..1A-71

Inspection of ECM and Its Circuits ....................1A-72

Fuel Injector Circuit Check ................................1A-85

Fuel Pump and Its Circuit Check.......................1A-86

Fuel Pressure Check.........................................1A-88

Idle Air Control System Check ..........................1A-89

Idle Air Control Circuit Check ............................1A-92

Throttle Valve Opening Signal Inspection .........1A-93

A/C Control System Check (Vehicle with A/C) ..1A-93

Electric Load Signal Circuit Check ....................1A-98

NOTE

For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual

mentioned in the “FOREWORD” of this manual.

1-ii Table of Contents

Radiator Fan Control System Check.................1A-99

Radiator Fan Control Circuit Check ................1A-101

Power Steering Pressure (PSP) Switch Signal

Circuit Check.................................................1A-104

Generator Control Signal Circuit Check .......... 1A-106

Repair Instructions ..........................................1A-107

Idle Speed / Idle Air Control (IAC) Duty

Inspection...................................................... 1A-107

Special Tools and Equipment .........................1A-109

Special Tool .................................................... 1A-109

Aux. Emission Control Devices ............. 1B-1

Repair Instructions ..............................................1B-1

EVAP Canister Inspection................................... 1B-*

EVAP Canister Purge Inspection ........................ 1B-*

EVAP Canister Purge Valve and Its Circuit

Inspection.......................................................... 1B-*

EVAP Canister Purge Valve Inspection .............. 1B-*

Vacuum Passage Inspection............................... 1B-1

Vacuum Hose Inspection ....................................1B-1

PCV Hose Inspection .......................................... 1B-*

PCV Valve Inspection ......................................... 1B-*

Special Tools and Equipment ............................. 1B-*

Recommended Service Material ......................... 1B-*

Special Tool ........................................................ 1B-*

Engine Electrical Devices....................... 1C-1

Repair Instructions ..............................................1C-1

Idle Air Control (IAC) Valve Removal and

Installation.........................................................1C-1

Idle Air Control (IAC) Valve Inspection................1C-1

Oil Control Valve Removal and Installation.........1C-2

Oil Control Valve Inspection................................1C-2

Engine Control Module (ECM) Removal and

Installation......................................................... 1C-*

Manifold Absolute Pressure (MAP) Sensor

Inspection.......................................................... 1C-*

Throttle Position (TP) Sensor On-Vehicle

Inspection.......................................................... 1C-*

Throttle Position (TP) Sensor Removal and

Installation......................................................... 1C-*

Intake Air Temperature (IAT) Sensor

Removal and Installation................................... 1C-*

Intake Air Temperature (IAT) Sensor

Inspection.......................................................... 1C-*

Engine Coolant Temperature (ECT) Sensor

Removal and Installation................................... 1C-*

Engine Coolant Temperature (ECT) Sensor

Inspection.......................................................... 1C-*

Heated Oxygen Sensor (HO2S) Removal and

Installation.........................................................1C-2

Oxygen Sensor Heater Inspection ......................1C-3

Camshaft Position (CMP) Sensor Removal

and Installation ..................................................1C-3

Camshaft Position (CMP) Sensor and Its

Circuit Inspection .............................................. 1C-*

Crankshaft Position (CKP) Sensor Removal

and Installation .................................................. 1C-*

Crankshaft Position (CKP) Sensor and Its

Circuit Inspection............................................... 1C-*

Vehicle Speed Sensor (VSS) and Its Circuit

Inspection.......................................................... 1C-*

Main Relay, Fuel Pump Relay, A/C

Compressor Relay and A/C Condenser Fan

Relay Inspection................................................ 1C-*

Radiator Fan Relay No.1, No.2 and No.3

Inspection.......................................................... 1C-*

Specifications.......................................................1C-3

Tightening Torque Specifications........................1C-3

Engine Mechanical .................................. 1D-1

General Description .............................................1D-1

Engine Construction Description .........................1D-1

Variable Valve Timing (VVT) System

Description ........................................................1D-2

Diagnostic Information and Procedures............1D-5

Compression Check............................................1D-5

Engine Vacuum Check........................................1D-6

Valve Lash (Clearance) Inspection .....................1D-7

Repair Instructions ............................................1D-10

Air Cleaner Element Removal and Installation ..1D-10

Air Cleaner Element Inspection and Cleaning ..1D-10

Accelerator Cable Adjustment...........................1D-10

Throttle Body Components ...............................1D-11

Throttle Body On-Vehicle Inspection.................1D-11

Throttle Body Removal and Installation ............1D-11

Throttle Body Disassembly and Assembly........1D-12

Throttle Body Cleaning......................................1D-12

Throttle Body and Intake Manifold

Components....................................................1D-13

Throttle Body and Intake Manifold Removal

and Installation ................................................1D-14

Cylinder Head Cover Removal and

Installation .......................................................1D-15

Engine Mountings Components ........................1D-17

Engine Assembly Removal and Installation ......1D-18

Timing Chain Cover Components .....................1D-21

Timing Chain Cover Removal and Installation ..1D-22

Timing Chain Cover Cleaning and Inspection...1D-24

Timing Chain and Chain Tensioner

Components....................................................1D-25

Timing Chain and Chain Tensioner Removal

and Installation ................................................1D-26

Timing Chain and Chain Tensioner Inspection ..1D-29

Camshaft, Tappet and Shim Components ........1D-30

Camshaft, Tappet and Shim Removal and

installation .......................................................1D-30

Camshaft, Tappet and shim Inspection.............1D-33

Valves and Cylinder Head Components ...........1D-36

Valves and Cylinder Head Removal and

Installation .......................................................1D-37

Valves and Cylinder Head Disassembly and

Assembly.........................................................1D-39

Valves and Valve Guides Inspection.................1D-41

Cylinder Head Inspection ..................................1D-43

Valve Spring Inspection ....................................1D-44

Table of Contents 1-iii

Pistons, Piston Rings and Connecting Rods

Components....................................................1D-45

Pistons, Piston Rings and Connecting Rods

Removal and Installation.................................1D-46

Pistons, Piston Rings, Connecting Rods and

Cylinders Disassembly and Assembly ............1D-47

Cylinders, Pistons and Piston Rings

Inspection........................................................1D-48

Piston Pins and Connecting Rods Inspection ...1D-50

Crank Pin and Connecting Rod Bearings

Inspection........................................................1D-51

Main Bearings, Crankshaft and Cylinder

Block Components..........................................1D-55

Main Bearings, Crankshaft and Cylinder

Block Removal and Installation.......................1D-56

Crankshaft Inspection .......................................1D-59

Main Bearings Inspection..................................1D-60

Sensor Plate Inspection ....................................1D-64

Rear Oil Seal Inspection ...................................1D-65

Flywheel Inspection ..........................................1D-65

Cylinder Block Inspection..................................1D-65

Specifications.....................................................1D-66

Tightening Torque Specifications......................1D-66

Special Tools and Equipment ...........................1D-67

Recommended Service Material .......................1D-67

Special Tool ......................................................1D-67

Engine Lubrication System .................... 1E-1

General Description ............................................. 1E-1

Engine Lubrication Description ...........................1E-1

Diagnostic Information and Procedures.............1E-*

Oil Pressure Check ..............................................1E-*

Repair Instructions .............................................. 1E-2

Oil Pan and Oil Pump Strainer Components.......1E-2

Oil Pan and Oil Pump Strainer Removal and

Installation.........................................................1E-2

Oil Pan and Oil Pump Strainer Cleaning..............1E-*

Oil Pump Components ........................................1E-4

Oil Pump Removal and Installation......................1E-*

Oil Pump Disassembly and Assembly ................ 1E-4

Oil Pump Inspection .............................................1E-*

Specifications....................................................... 1E-6

Tightening Torque Specifications........................1E-6

Special Tools and Equipment ............................. 1E-6

Recommended Service Material .........................1E-6

Special Tool ........................................................ 1E-6

Engine Cooling System ........................... 1F-*

General Description ..............................................1F-*

Cooling System Description .................................1F-*

Coolant Description..............................................1F-*

Schematic and Routing Diagram.........................1F-*

Coolant Circulation...............................................1F-*

Diagnostic Information and Procedures.............1F-*

Engine Cooling Symptom Diagnosis....................1F-*

Repair Instructions ...............................................1F-*

Cooling System Components ..............................1F-*

Coolant Level Check............................................1F-*

Engine Cooling System Inspection and

Cleaning .............................................................1F-*

Cooling System Flush and Refill ..........................1F-*

Cooling Water Pipes or Hoses Removal and

Installation ..........................................................1F-*

Thermostat Removal and Installation...................1F-*

Thermostat Inspection..........................................1F-*

Water Valve (If Equipped) Removal and

Installation ..........................................................1F-*

Water Valve (If Equipped) Inspection...................1F-*

Radiator Cooling Fan On-Vehicle Inspection .......1F-*

Radiator Cooling Fan Relay Inspection................1F-*

Radiator Cooling Fan Removal and

Installation ..........................................................1F-*

Radiator On-Vehicle Inspection and Cleaning .....1F-*

Radiator Removal and Installation .......................1F-*

Water Pump / Generator Drive Belt Tension

Inspection and Adjustment.................................1F-*

Water Pump / Generator Drive Belt Removal

and Installation ...................................................1F-*

Water Pump Removal and Installation.................1F-*

Water Pump Inspection........................................1F-*

Specifications........................................................1F-*

Tightening Torque Specifications.........................1F-*

Special Tools and Equipment ..............................1F-*

Recommended Service Material ..........................1F-*

Special Tool .........................................................1F-*

Fuel System .............................................1G-1

Precautions........................................................... 1G-*

Precautions on Fuel System Service .................. 1G-*

General Description ............................................. 1G-*

Fuel System Description ..................................... 1G-*

Fuel Delivery System Description ....................... 1G-*

Fuel Pump Description........................................ 1G-*

Schematic and Routing Diagram........................ 1G-*

Fuel Delivery System Diagram............................ 1G-*

Diagnostic Information and Procedures............ 1G-*

Fuel Pressure Inspection .................................... 1G-*

Fuel Cut Operation Inspection ............................ 1G-*

Repair Instructions ............................................. 1G-1

Fuel System Components................................... 1G-*

Fuel Pressure Relief Procedure .......................... 1G-*

Fuel Leakage Check Procedure.......................... 1G-*

Fuel Lines On-Vehicle Inspection ....................... 1G-*

Fuel Pipe Removal and Installation.................... 1G-1

Fuel Injector On-Vehicle Inspection .................... 1G-*

Fuel Injector Removal and Installation ............... 1G-2

Fuel Injector Inspection ...................................... 1G-3

Fuel Pressure Regulator On-Vehicle

Inspection.......................................................... 1G-*

Fuel Pressure Regulator Removal and

Installation ........................................................ 1G-4

Fuel Filler Cap Inspection ................................... 1G-*

Fuel Tank Removal and Installation................... 1G-5

Fuel Tank Inspection........................................... 1G-*

Fuel Tank Purging Procedure ............................. 1G-*

Fuel Tank Inlet Valve Removal and

Installation ......................................................... 1G-*

1-iv Table of Contents

Fuel Tank Inlet Valve Inspection ......................... 1G-*

Fuel Pump On-Vehicle Inspection....................... 1G-*

Fuel Pump Assembly Components..................... 1G-*

Fuel Pump Assembly Removal and

Installation......................................................... 1G-*

Fuel Pump Assembly Disassembly and

Assembly .......................................................... 1G-*

Fuel Pump Assembly Inspection......................... 1G-*

Specifications...................................................... 1G-8

Tightening Torque Specifications....................... 1G-8

Special Tools and Equipment ............................. 1G-*

Recommended Service Material ......................... 1G-*

Special Tool ........................................................ 1G-*

Ignition System......................................... 1H-*

General Description ............................................. 1H-*

Ignition System Construction .............................. 1H-*

Schematic and Routing Diagram........................ 1H-*

Ignition System Wiring Circuit Diagram............... 1H-*

Component Location ........................................... 1H-*

Ignition System Components Location................ 1H-*

Diagnostic Information and Procedures............ 1H-*

Ignition System Symptom Diagnosis................... 1H-*

Ignition System Check ........................................ 1H-*

Ignition Spark Test .............................................. 1H-*

Repair Instructions .............................................. 1H-*

High-Tension Cord Removal and Installation...... 1H-*

High-Tension Cord Inspection............................. 1H-*

Spark Plug Removal and Installation .................. 1H-*

Spark Plug Inspection ......................................... 1H-*

Ignition Coil Assembly (Including Igniter)

Removal and Installation................................... 1H-*

Ignition Coil Assembly (Including Igniter)

Inspection.......................................................... 1H-*

Ignition Timing Inspection ................................... 1H-*

Specifications....................................................... 1H-*

Tightening Torque Specifications........................ 1H-*

Special Tools and Equipment ............................. 1H-*

Special Tool ........................................................ 1H-*

Starting System ..........................................1I-*

Schematic and Routing Diagram..........................1I-*

Cranking System Circuit Diagram .........................1I-*

Diagnostic Information and Procedures..............1I-*

Cranking System Symptom Diagnosis..................1I-*

Cranking System Test...........................................1I-*

Repair Instructions ................................................1I-*

Starting Motor Dismounting and Remounting .......1I-*

Starting Motor Components ..................................1I-*

Starting Motor Inspection ......................................1I-*

Specifications.........................................................1I-*

Cranking System Specifications............................1I-*

Tightening Torque Specifications..........................1I-*

Special Tools and Equipment ...............................1I-*

Recommended Service Material ...........................1I-*

Charging System...................................... 1J-*

General Description ..............................................1J-*

Battery Description............................................... 1J-*

Generator Description .......................................... 1J-*

Diagnostic Information and Procedures.............1J-*

Battery Inspection ................................................ 1J-*

Generator Symptom Diagnosis ............................ 1J-*

Generator Test (Undercharged Battery

Check)................................................................ 1J-*

Generator Test (Overcharged Battery Check) ..... 1J-*

Repair Instructions ...............................................1J-*

Jump Starting in Case of Emergency................... 1J-*

Battery Dismounting and Remounting ................. 1J-*

Generator Dismounting and Remounting............. 1J-*

Generator Components........................................ 1J-*

Generator Inspection............................................ 1J-*

Specifications........................................................1J-*

Charging System Specifications .......................... 1J-*

Tightening Torque Specifications......................... 1J-*

Exhaust System........................................1K-*

General Description ............................................. 1K-*

Exhaust System Description ............................... 1K-*

Repair Instructions .............................................. 1K-*

Exhaust System Components............................. 1K-*

Exhaust Manifold Components ........................... 1K-*

Exhaust Manifold Removal and Installation ........ 1K-*

Exhaust Pipe Removal and Installation............... 1K-*

Specifications....................................................... 1K-*

Tightening Torque Specifications........................ 1K-*

Precautions: 1-1

Precautions

Precautions for Engine

S3RH0B1000001

Air Bag Warning

Refer to “Air Bag Warning in Section 00 in related manual”.

Precautions on Engine Service

Refer to “Precautions on Engine Service in Section 1A”.

Precautions in Diagnosing Trouble

Refer to “Precautions in Diagnosing Trouble in Section 1A”.

Precautions on Fuel System Service

Refer to “Precautions on Fuel System Service in Section 1G in related manual”.

1A-1 Engine General Information and Diagnosis:

Engine General Information and Diagnosis

Precautions

Precautions on Engine Service

S3RH0B1100001

CAUTION

!

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 12-volt electrical system is capable of violent and

damaging short circuits.

When performing any work where electrical terminals

can be grounded, ground cable of the battery should

be disconnected at battery.

• Any time the air cleaner, throttle body 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.

Precautions in Diagnosing Trouble

S3RH0B1100002

• Don’t disconnect couplers from ECM, battery cable

from battery, ECM ground wire harness from engine

or main fuse before confirming diagnostic information

(DTC, etc.) stored in ECM memory. Such

disconnection will erase memorized information in

ECM memory.

• Diagnostic information stored in ECM memory can be

cleared as well as checked by using SUZUKI scan

tool. Before using scan tool, read its Operator’s

(Instruction) Manual carefully to have good

understanding as to what functions are available and

how to use it.

• Be sure to read “Precautions for Electrical Circuit

Service in Section 00 in related manual” before

inspection and observe what is written there.

• ECM Replacement

When substituting a known-good ECM, check for the

following conditions. Neglecting this check may cause

damage to a known-good ECM.

– Resistance value of all relays, actuators is as

specified respectively.

– MAP sensor and TP sensor are in good condition

and none of power circuits of these sensors is

shorted to ground.

Engine General Information and Diagnosis: 1A-2

General Description

Statement on Cleanliness and Care

S3RH0B1101001

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 an inch).

Accordingly, when any internal engine parts are

serviced, care and cleanliness are important.

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 surfaces 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 four cylinders of the

engine are identified by numbers; No.1 (1), No.2 (2),

No.3 (3) and No.4 (4) counted from crankshaft pulley

side to flywheel side.

Engine Diagnosis General Description

S3RH0B1101002

This vehicle is equipped with an engine and emission

control system which are under control of ECM.

The engine and emission control system in this vehicle

are controlled by ECM. ECM has an On-Board

Diagnostic system which detects a malfunction in this

system and abnormality of those parts that influence the

engine exhaust emission. When diagnosing engine

troubles, be sure to have full understanding of the outline

of “On-Board Diagnostic System Description” and each

item in “Precautions in Diagnosing Trouble” and execute

diagnosis according to “Engine and Emission Control

System Check”.

There is a close relationship between the engine

mechanical, engine cooling system, ignition system,

exhaust system, etc. and the engine and emission

control system in their structure and operation. In case of

an engine trouble, even when the malfunction indicator

lamp (MIL) doesn’t turn ON, it should be diagnosed

according to this flow table.

On-Board Diagnostic System Description

S3RH0B1101003

ECM diagnosis troubles which may occur in the area

including the following parts when the ignition switch is

ON and the engine is running, and indicates the result by

turning on or flashing malfunction indicator lamp (1).

• Heated oxygen sensor

• ECT sensor

• TP sensor

• IAT sensor

• MAP sensor

• CMP sensor

• CKP sensor

• Knock sensor (if equipped)

• VSS

• Barometric pressure sensor

• Camshaft position control

• Oil control valve (Camshaft Position Control)

• CPU (Central Processing Unit) of ECM

ECM and malfunction indicator lamp (1) operate as

follows.

• Malfunction indicator lamp (1) lights when the ignition

switch is turned ON (but the engine at stop) with the

diagnosis switch terminal ungrounded regardless of

the condition of Engine and Emission control system.

This is only to check the malfunction indicator lamp (1)

in the combination meter and its circuit.

• If the above areas of Engine and Emission control

system is free from any trouble after the engine start

(while engine is running), malfunction indicator lamp

(1) turns OFF.

• When ECM detects a trouble which has occurred in

the above areas, it makes malfunction indicator lamp

(1) turn ON while the engine is running to warn the

driver of such occurrence of trouble and at the same

time it stores the trouble area in ECM back-up

memory. (The memory is kept as it is even if the

trouble was only temporary and disappeared

immediately. And it is not erased unless the power to

ECM is shut off for specified time or it is cleared by

SUZUKI scan tool.)

ECM also indicates trouble area in memory by means

of flashing of malfunction indicator lamp (1) at the time

of inspection. (i.e. when diagnosis switch terminal (2)

is connected to ground terminal (3) with a service wire

(4) and ignition switch is turned ON.)

1

2

3

4

I2RH0B110001-01

1A-3 Engine General Information and Diagnosis:

NOTE

When a trouble occurs in the above areas

and disappears soon while the diagnosis

switch terminal is ungrounded and the

engine is running, malfunction indicator lamp

(1) lights and remains ON as long as the

trouble exists but it turns OFF when the

normal condition is restored.

Driving cycle

A “Driving Cycle” consists of engine startup, driving

mode where a malfunction would be detected if present,

and engine shutoff.

2 driving cycles detection logic

The malfunction detected in the first driving cycle is

stored in ECM memory (in the form of pending DTC) but

the malfunction indicator lamp does not light at this time.

It lights up at the second detection of same malfunction

also in the next driving cycle.

Pending DTC

Pending DTC means a DTC detected and stored

temporarily at 1 driving cycle of the DTC which is

detected in the 2 driving cycle detection logic.

Data link connector (DLC)

DLC (1) is in compliance with SAE J1962 in the shape of

connector and pin assignment.

Serial data line (K line of ISO 9141) (3) is used for

SUZUKI scan tool to communicate with ECM, TCM, ABS

control module and Air bag SDM.

SUZUKI serial data line (6) is used for SUZUKI scan tool

to communicate with immobilizer control module.

Engine and Emission Control System

Description

S3RH0B1101004

The engine and emission control system is divided into 4

major sub-systems: air intake system, fuel delivery

system, electronic control system and emission control

system.

Air intake system includes air cleaner, throttle body, IAC

valve and intake manifold.

Fuel delivery system includes fuel pump, delivery pipe,

fuel pressure regulator, etc.

Electronic control system includes ECM, various sensors

and controlled devices.

Emission control system includes EVAP and PCV

system.

1

2

3

4

I3RH0A110003-01

2. B +

4. ECM ground

5. Body ground

I3RH0A110002-01

Engine General Information and Diagnosis: 1A-4

Air Intake System Description

S3RH0B1101005

The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3), idle air

control valve (4) and intake manifold (5).

The air (by the amount corresponding to manifold absolute pressure (6) and engine speed) is filtered by the air

cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each combustion

chamber.

When the idle air control valve is opened according to the signal from ECM, the air (7) bypasses the throttle valve (8)

through bypass passage and is finally drawn into the intake manifold.

Electronic Control System Description

S3RH0B1101006

The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2)

ECM which controls various devices according to the signals from the sensors and 3) various controlled devices.

Functionally, it is divided into the following sub systems:

• Fuel injection control system

• Ignition control system

• Idle speed control system

• Fuel pump control system

• Radiator fan control system

• Evaporative emission control system

• Oxygen sensor heater control system

• Camshaft position control system

• A/C control system (if equipped)

Also, with A/T model, ECM sends throttle valve opening signal, engine torque signal, A/C compressor operation signal

and coolant temp. signal to transmission control module to control A/T.

5

4

2

1

3

7

6

8

I2RH0B110005-01

1A-5 Engine General Information and Diagnosis:

Engine and Emission Control System Flow Diagram

EVAP

CANISTER

PURGE

VALVE

AIR

CLEANER

IAT

SENSOR

FUEL TANK

FUEL

PUMP

TP

SENSOR

IAC

VALVE

THROTTLE

BODY

MAP

SENSOR

INTAKE

MANIFOLD

EXHAUST

MANIFOLD

EXHAUST GAS

AIR

FUEL

VAPOR

THREE-WAY

CATAL YST

EXHAUST

PIPE

EVAP

CANISTER

CHECK

VALVE

FUEL

INJECTOR

ECT

SENSOR

TACHO

METER

SPEED-

METER

VSS

STOP LAMP

SWITCH

ELECTRIC

LOAD

RADIATOR

FAN

TCM

HEATER

CONTROL

BAROMETRIC

PRESSURE

SENSOR

HO2S-1

IMMOBILIZER

CONTROL MODULE

MIL

A/C EVAPRATOR

INLET AIR

TEMP. SENSOR ,

A/C EVAPRATOR

OUTLET AIR

TEMP. SENSOR ,

A/C SWITCH

SIGNAL

THROTTLE SIGNAL,

WATER TEMP. SIGNAL

A/C COMPRESSOR

CLUTCH

AND CONDENSER

FAN RELAY

D RANGE SIGNAL

TRANSMISSION

RANGE SIGNAL

ENGINE

CMP

SENSOR

CKP

SENSOR

KNOCK

SENSOR

IGNITION

COIL

WITH IGNITOR

CMP OIL

CONTROL

VALVE

I3RH0B110001-01

Engine General Information and Diagnosis: 1A-6

ECM Input / Output Circuit Diagram

BLK

C41-13

17

1

5V

12V

2+B

1

6

5

IG1

C41-9

C41-11

C41-23

C41-22

C41-16

C41-26

C41-14

C41-15

C41-10

C41-25

C41-13

C41-7

G04-14

C41-10

G03-13

C41-21

C41-31

C41-8

C41-6

C41-4

C41-24

G04-18

G04-3

G04-10

G04-6

G04-5

C41-30

C41-2

C41-1

C41-3

G04-23

G03-11

C41-20

C41-19

27

+B

28

29

30

31

32

33

IG1

34

35

L+

H+

H-

L- 58

59

IG2

IG11

IG12

50

IG

IG1

ST

13

IG2

49

54

+

IG11

ABS

TCM

SDM

26

9

4

7

+BB

: 56

: 57

10

BLU

BLU/YEL

BLU/WHT

BLU/RED

BLU/GRN

GRN/RED

BLU/BLK

BRN

GRN/RED

GRN/YEL

41

42

GRN/WHT

BLK/WHT

WHT/RED

BRN/WHT

BLK/RED

BLK/YEL

BLK/ORN

BLK

YEL/BLK

GRY/RED

GRY/BLU

LT GRN/RED

LT GRN

LT GRN/BLK

ORN

RED

WHT

PNK/BLK

YEL/WHT

BLU

BLK/WHT

G04-17

+BB

47

YEL/BLK

48

45

46

G03-8

YEL

BLK/RED

52

53

WHT

ORN

: 12V

: 5V

BLU/WHT

BLK/YEL

BLK/RED

BLK/ORN

G04-1

8

11

G04-11

G04-9 BLU/YEL

19

21

20

22

RED/BLU

BRN/YEL

BLK

WHT

YEL

23

C41-5

BLK

RED/BLU

C41-12

24

WHT/BLK

55

17

G03-12

12

PLL

G03-1

G03-6

G03-14

G04-8

G03-5

G03-4

G04-2

G04-24

PRND2L

IG11

43

IG1

+BB

51

14

GRY/RED

PPL/WHT

GRY/BLK

BRN/YEL

WHT/GRN

GRN/WHT

44

G03-9

YEL/GRN

LT GRN/RED

39

3

LT GRN/BLK

36

DN

TS

GND MON

38

40

PPL/YEL

G03-7

C41-27

G04-15

G03-17

G04-16

G03-10

G04-7

GRN/BLK

BLU/ORN

BLU/BLK

IG2

15

16

18

WHT

BLU

BLKBLK

PPL/WHT

PNK/BLK

PNK/GRN

+BB

ORN

37

25

G04-12

GRN

G04-21

BLK/YEL

RED

YEL

I3RH0B110002-01

1A-7 Engine General Information and Diagnosis:

Terminal Arrangement of ECM Coupler (Viewed from Harness Side)

1. CKP sensor 21. A/C compressor relay 41. Ignition coil assembly (for No.1 and No.4 spark plugs)

2. CMP sensor 22. A/C compressor magnet clutch 42. Ignition coil assembly (for No.2 and No.3 spark plugs)

3. VSS 23. Power steering pressure switch 43. Stop lamp switch

4. MAP sensor 24. Generator 44. Stop lamp

5. Knock sensor 25. Immobilizer control module 45. Lighting switch

6. TP sensor 26. Data link connector 46. Position lamp

7. ECT sensor 27. Injector No.1 47. Rear defogger switch (built-in A/C control module)

8. IAT sensor 28. Injector No.2 48. Rear defogger

9. Heated oxygen sensor 29. Injector No.3 49. Ignition switch

10. A/C evaporator outlet air temp. sensor 30. Injector No.4 50. Main relay

11. A/C evaporator inlet air temp. sensor 31. IAC valve 51. Transmission range switch (A/T)

12. TCM (A/T) 32. EVAP canister purge valve 52. Starting motor

13. Park/neutral position switch (A/T) 33. Fuel pump relay 53. Shield wire

14. ABS control module 34. Fuel pump 54. Main fuse

15. Blower fan motor 35. Radiator fan relay No.1 55. Barometric pressure sensor

16. A/C control module 36. Radiator fan motor 56. Engine ground

17. ECM 37. Oil control valve 57. Body ground

18. A/C pressure switch 38. Malfunction indicator lamp 58. Radiator fan relay No.2

19. A/C condenser fan relay 39. Combination meter 59. Radiator fan relay No.3

20. A/C condenser fan motor 40. Diagnosis connector

C41 (31P) G04 (24P) G03 (17P)

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1234567

1112

9101113 12141516

1617

12

78

1314

34

910

15

1718

8

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I2RH0B110008-01

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Suzuki Liana RH418 Supplementary Service Manual

Suzuki Liana RH418 Supplementary Service Manual

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