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 IMPORTANT
WARNING/CAUTION/NOTE WARNING:
Please read this manual and follow its instructions
For vehicles equipped with a Supplemental
carefully. To emphasize special information, the
Restraint (Air Bag) System:
words WARNING, CAUTION and NOTE have spe-

Service on and around the air bag system
cial meanings. Pay special attention to the messages
components or wiring must be performed
highlighted by these signal words.
only by an authorized SUZUKI dealer.
Refer to “Air Bag System Components and
WARNING: Wiring Location View” under “General De-
Indicates a potential hazard that could result scription” in air bag system section in order
in death or injury. to confirm whether you are performing ser-
vice on or near the air bag system compo-
nents or wiring. Please observe all WARN-
CAUTION: INGS and “Service Precautions” under “On-
Indicates a potential hazard that could result Vehicle Service” in air bag system section
in vehicle damage. before performing service on or around the
air bag system components or wiring. Fail-
ure to follow WARNINGS could result in
NOTE:
unintentional activation of the system or
Indicates special information to make mainte-
could render the system inoperative. Either
nance easier or instructions clearer.
of these two conditions may result in severe
injury.

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 unintended air bag sys-
tem activation.

Do not modify the steering wheel, instru-
ment panel or any other air bag system com-
ponent (on or around air bag system compo-
nents or wiring). Modifications can adverse-
WARNING: ly affect air bag system performance and
This service manual is intended for authorized lead to injury.
SUZUKI dealers and qualified service me-
If the vehicle will be exposed to tempera-
chanics only. Inexperienced mechanics or tures over 93 C (200 F) (for example, during
mechanics without the proper tools and a paint baking process), remove the air bag
equipment may not be able to properly per- system components (air bag (inflator) mod-
form the services described in this manual. ule, sensing and diagnostic module (SDM),
Improper repair may result in injury to the me- seat belt pretensioner (if equipped) before-
chanic and may render the vehicle unsafe for hand to avoid component damage or unin-
the driver and passengers. tended activation.

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 FOREWORD
This SUPPLEMENTARY SERVICE MANUAL is a supplement to SQ416/SQ420/SQ625 SER-
VICE MANUAL. It has been prepared exclusively for the following applicable model.

Applicable model:
SQ416/SQ420 Canvas Top Model

It describes only different service information of SQ416/SQ420 canvas top model as compared
with SQ416/SQ420/SQ625 SERVICE MANUAL.
Therefore, whenever servicing SQ416/SQ420 canvas top 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 (lubricants, 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 unit of standard specifications among others.
Therefore, note that illustrations may differ from the unit being actually serviced. The right is re-
served to make changes at any time without notice.

RELATED MANUAL:
Manual Name Manual No.
SQ416/SQ420/SQ625 Service Manual 99500-65D00
SQ416/SQ420/SQ625 Unit Repair Manual for Manual
Transmission, Automatic Transmission, Transfer and 99501-65D00
Differential
SQ416/SQ420/SQ625 Wiring Diagram Manual 99512-65D01

OVERSEAS SERVICE DEPARTMENT

COPYRIGHT SUZUKI MOTOR CORPORATION 1998

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 TABLE OF CONTENTS SECTION 0A
GENERAL INFORMATION
1B
General Information 0A
HEATING AND AIR 3B1
CONDITIONING
Air Conditioning 1B 3C1
STEERING, SUSPENSION,
WHEELS AND TIRES 3D
Power Steering (P/S) System 3B1
Air Bag Steering Wheel and 3E
Column 3C1
Front Suspension 3D 3F
Rear Suspension 3E
4A2
Wheel and Tires 3F
DRIVE SHAFT/PROP. SHAFT 5
Front Drive Shaft/Shaft
4A2
Bearing, Oil Seal 5A
BRAKES 5
Brake Pipe/Hose /Master 6
Cylinder 5A

ENGINE
6E1
General Information and
6 6H
Diagnosis
Engine and Emission Control
6E1 7B1
System (SFI for G16/J20)
Charging System 6H
8B
TRANSMISSION, CLUTCH AND
DIFFERENTIAL
8C
Automatic Transmission 7B1
BODY ELECTRICAL SYSTEM 8D
Lighting System 8B
Instrumentation/Driver
9
8C
Information
Windows, Mirrors, Security 10A
8D
and Lock
9 10B
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt 10A
Air Bag System 10B

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 GENERAL INFORMATION 0A-1

0A
SECTION 0A

GENERAL INFORMATION
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 2
Precautions for Vehicle Equipped with a Supplemental Restraint (Air Bag) System . . . . . . . . . . . . . . . . 0A- 2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 2
Servicing and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 3

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 0A-2 GENERAL INFORMATION

PRECAUTIONS
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM
WARNING:

The configuration of air bag system parts are as shown in
the figure. When it is necessary to service (remove, rein-
stall and inspect) these parts, be sure to follow proce-
dures described in SECTION 10B. Failure to follow proper
procedures could result in possible air bag system activa-
tion, personal injury, damage to parts or air bag system
being unable to activate when necessary.

If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag system
be repaired first, to help avoid unintended air bag system
activation.

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

If the vehicle will be exposed to temperatures over 93
C
(200
F) (for example, during a paint baking process), re-
move the air bag system components beforehand to avoid
component damage or unintended air bag system activa-
tion.

1. Air bag wire harness 5. Contact coil

2. Passenger air bag 6. Driver air bag (inflator)
(inflator) module module
3. SDM 7. Seat belt pretensioner
4. DLC (if equipped)

DIAGNOSIS

When troubleshooting air bag system, be sure to follow
“DIAGNOSIS” in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect diag-
nosis, and incorrect parts replacement.

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

WARNING:
Never attempt to measure the resistance of the air bag (in-
flator) modules (driver and passenger) and seat belt preten-
tioners (driver and passenger). It is very dangerous as the
electric current from the tester may deploy the air bag or ac-
tivate the pretensioner.

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 GENERAL INFORMATION 0A-3

SERVICING AND HANDLING

ALWAYS CARRY AIR BAG (INFLATOR) MODULE
WITH TRIM COVER (AIR BAG OPENING) AWAY
FROM BODY. WARNING:
Many of service procedures require disconnection of “AIR
BAG” fuse and all air bag (inflator) module(s) from initiator
circuit to avoid an accidental deployment.
Driver and Passenger Air Bag (Inflator) Modules

For handling and storage of a live air bag (inflator) module,
select a place where the ambient temperature below 65
C
(150
F), without high humidity and away from electric
noise.

When carrying a live air bag (inflator) module, make sure
the bag opening is pointed away from you. In case of an
accidental deployment, the bag will then deploy with mini-
mal chance of injury. Never carry the air bag (inflator)
module by the wires or connector on the underside of the
module. When placing a live air bag (inflator) module on
a bench or other surface, always face the bag up, away
from the surface. As the live passenger air bag (inflator)
module must be placed with its bag (trim cover) facing up,
place it on the workbench with a slit or use the workbench
ALWAYS PLACE AIR BAG (INFLATOR) MODULE vise to hold it securely at its lower mounting bracket. This
ON WORKBENCH WITH TRIM COVER (AIR BAG
OPENING) UP, AWAY FROM LOOSE OBJECTS.
is necessary so that a free space is provided to allow the
air bag to expand in the unlikely event of accidental de-
ployment. Otherwise, personal injury may result.

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

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

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

1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket

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 0A-4 GENERAL INFORMATION

WARNING:
SDM

During service procedures, be very careful when handling
a Sensing and Diagnostic Module (SDM). Never strike or
jar the SDM.
Never power up the air bag system when the SDM is not
rigidly attached to the vehicle. All SDM and mounting
bracket fasteners must be carefully torqued and the arrow
must be pointing toward the front of the vehicle to ensure
proper operation of the air bag system.
The SDM could be activated when powered while not rigid-
ly attached to the vehicle which could cause deployment
and result in personal injury.

WARNING:
Driver and Passenger Seat Belt Pretensioners

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

Never carry seat belt pretensioner by wire or connector of
pretensioner. When placing a live seat belt pretensioner
on the workbench or some place like that, be sure not to
lay it with its exhaust hole provided side facing down. It is
also prohibited to put something on its face with an ex-
haust hole or to put a seat belt pretensioner on top of
another. Otherwise, personal injury may result.

Never dispose of live (inactivated) seat belt pretensioners
NG NG (driver and passenger). If disposal is necessary, be sure
to activate them according to activation procedures de-
scribed in SECTION 10B before disposal.

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

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

1. Exhaust hole

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 GENERAL INFORMATION 0A-5

CAUTION:

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

When servicing parts other than air bag system, if shocks
may be applied to air bag system component parts, re-
move those parts beforehand.

When handling the air bag (inflator) modules (driver and
passenger), seat belt pretensioners (driver and passen-
ger) or SDM, be careful not to drop it or apply an impact to
it. If an excessive impact was applied (e.g., dropped from
a height of 91.4 cm (3 feet) or more), never attempt disas-
sembly or repair but replace it with a new one.

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

Air bag wire harness can be identified easily as it is cov-
ered with a yellow protection tube. Be very careful when
handling it.

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

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

Never use air bag system component parts from another
vehicle.

When using electric welding, be sure to temporarily dis-
able air bag system referring to “Disabling Air Bag Sys-
tem” described in “Service Precautions” under “On-Ve-
hicle Service” in SECTION 10B.

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

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

After vehicle is completely repaired, perform “Air Bag
Diagnostic System Check” described in “Diagnosis” in
SECTION 10B.

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 AIR CONDITIONING (OPTIONAL) 1B-1

SECTION 1B

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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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 mainte-
nance. 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.

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 2

Major Components and Refrigerant
Flow of Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 2
Component Location in Engine Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 3
RECOVERY, EVACUATION AND CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 4
Procedure of Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 4
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 6
Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 6
Compression System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18

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 1B-2 AIR CONDITIONING (OPTIONAL)

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

MAJOR COMPONENTS AND REFRIGERANT FLOW OF AIR CONDITIONING

SYSTEM

1. Compressor
2. Magnet clutch
3. Condenser
4. Receiver State of Refrigerant
5. Dual pressure switch Liquid
6. Expansion valve
7. Evaporator Vapor
8. Blower motor Condenser
Superheated Vapor Cooling air
9. Heater core
10. Dryer

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 AIR CONDITIONING (OPTIONAL) 1B-3

COMPONENT LOCATION IN ENGINE ROOM

G16 LH steering vehicle

10

1. Liquid pipe 6. Compressor delivery hose

2. Compressor suction hose 7. Compressor
3. Dual pressure switch 8. Suction pipe
J20 LH steering vehicle 4. Condenser outlet pipe 9. High pressure service valve
5. Condenser 10. Low pressure service valve
10

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 1B-4 AIR CONDITIONING (OPTIONAL)

G16 LH steering vehicle shown

RECOVERY, EVACUATION AND
CHARGING
PROCEDURE OF CHARGING
1) Make sure that hoses are routed properly after evacuating the
system.
2) Connect the manifold gauge set in position. Thus open refriger-
ant container valve to purge the charging line. Then open the low
pressure-side valve.

WARNING:
Make sure that high pressure-side valve is closed se-
curely.

3) Start engine and keep engine speed at 1,000 r/min. Then, oper-
ate air conditioning.
4) Charge A/C system with refrigerant in vapor state. At this time,
1. Manifold gauge set refrigerant container should be held upright.
2. High pressure side (Delivery side hose)
3. Low pressure side (Suction side pipe)

5) When refrigerant container is emptied, use following procedure

to replace it with a new refrigerant container.
a. Close low pressure valve.
b. Replace empty container with a refrigerant container which
has been charged with refrigerant. When using refrigerant
container tap valve, use following procedure for replace-
1. Needle ment.
2. Plate nut
3. Refrigerant i) Retract needle and remove refrigerant container tap valve
container by loosening its plate nut.
4. Handle
ii) Install previously-removed refrigerant container tap valve
to a new refrigerant container.
c. Purge any air existing in center charging hose.
When using refrigerant container tap valve, use following
procedure to purge air.
i) Once fully tighten refrigerant container tap valve and then
loosen (open) plate nut slightly.
ii) Open low pressure valve of manifold gauge set a little.
iii) As soon as refrigerant comes out with a “hiss” through a
clearance between refrigerant container and tap valve,
tighten plate nut as well as manifold gauge set low pres-
sure valve.
iv) Turn handle of tap valve clockwise so that its needle is
screwed into the new container to make a hole for refriger-
ant flow.

1. “Hiss”

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 AIR CONDITIONING (OPTIONAL) 1B-5

6) After the system has been charged with specified amount (350
– 450 g, 12.3 – 16.0 oz.) of refrigerant or when low and high pres-
sure gauges have indicated specified value below respectively,
close low pressure side valve of manifold gauge set.

Low pressure gauge when charged with specified amount

About 200 – 300 kPa (2 – 3 kg/cm2, 29 – 43 psi)
(At A/C inlet temperature 30 – 35_C, 86 – 95_F)

High pressure gauge when charged with specified amount

About 1370 – 1670 kPa (14 – 17 kg/cm2, 200 – 244 psi)
(At A/C inlet temperature 30 – 35_C, 86 – 95_F)

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 1B-6 AIR CONDITIONING (OPTIONAL)

ON-VEHICLE SERVICE
REFRIGERATING SYSTEM
CHECK AND SUPPLEMENT OF REFRIGERANT
To check if refrigerant is properly charged or not, perform “COR-
RECTIVE MEASURES FOR MALFUNCTION SYMPTOMS” in this
section.
As a result, if adjustment a proper amount of refrigerant is neces-
sary for refrigerant system.
Charge a proper amount of refrigerant to refrigerant system accord-
ing to charging procedure described in recovery, evacuation and
charging.

NOTE:
Do not perform an additional refrigerant charging to A/C sys-
tem. This cause it to overcharge.

CONDENSER ASSEMBLY
INSPECTION
Check a) condenser fins for blockage, b) condenser fittings for leak-
age, and c) condenser fins for damage.
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 con-
denser.

REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant by using recovery and recycling equipment.
Be sure to follow the instruction manual for the equipment.
The amount of compressor oil removed must be measured and
the same amount added to the system.
1. Lower stay 3) Remove front bumper assembly and lower stay (Refer to Sec-
2. Bolt
tion 9 “BODY SERVICE”).
4) Disconnect compressor delivery hose from condenser inlet fit-
tings.

NOTE:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust do not enter con-
denser.

1. Compressor delivery hose

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 AIR CONDITIONING (OPTIONAL) 1B-7

5) Disconnect coupler from dual pressure switch.

6) Disconnect condenser outlet pipe.
7) Disconnect condenser cooling fan motor coupler.

1. Dual pressure switch

2. Condenser cooling fan motor coupler
3. Condenser outlet pipe

8) Remove condenser with fan.

NOTE:
Be careful not to damage fins of condenser and radiator.

9) Remove cooling fan from condenser.

INSTALLATION
Reverse removal sequence to install condenser, noting following
point.
1) When replacing condenser, add 20 to 30 cc of refrigerating oil
from compressor suction-side.
2) Evacuate and charge system according to previously-described
procedure.

REPLACEMENT OF CONDENSER DRYER

REMOVAL
1) Remove condenser assembly from vehicle (refer to “CON-
DENSER ASSEMBLY REMOVAL” in this section).
2) Remove the cap using a hexagon wrench.
2

1. Condenser assembly
2. Condenser dryer section

3) Remove the filter from the receiver.

1. Filter

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 1B-8 AIR CONDITIONING (OPTIONAL)

4) Remove the dryer using a plier.

1. Dryer

INSTALLATION
Reverse removal sequence to install condenser dryer, according to
instruction manual with supply parts.

NOTE:

When replacing condenser dryer, add 40 cc of refrigerating
oil the same as compressor oil.

Do not remove the dryer from the plastic bag until just before
inserting it into the receiver.
1. Dryer
Install the condenser dryer with its double-layer portion fac-
ing the bottom of the receiver.

Cap Tightening Torque

: 12.5
2.5 N.m
: 1.25
0.25 kg-m
: 9
1.8 lb-ft

LH steering vehicle shown FILTER ELEMENT

REMOVAL
1) Disconnect negative cable at battery.
2) For vehicle with air bag system, disable air bag system. Refer
to DISABLING AIR BAG SYSTEM in Section 10B.

LH steering vehicle shown 3) Pull down glove box.

1. Glove box

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 AIR CONDITIONING (OPTIONAL) 1B-9

LH steering vehicle shown 4) Remove filter cover.

1. Filter cover

LH steering vehicle shown 5) Pull out filter element. Pull out upper filter first then the lower one.

1 1. Filter element

CLEAN
Blow off dust by compressed air from air outlet side of the filter ele-
ment.

1. Air flow

LH steering vehicle shown INSTALLATION

Reverse removal procedure for installation noting the followings:

Install filter into cooling unit directing arrow mark on its end face
to heater unit.

Enable air bag system after installation. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.

1. Ears

EVAPORATOR (COOLING UNIT)

REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag System” in
Section 10B.
3) Recover refrigerant by using recovery and recycling equipment.
Be sure to follow the instruction manual for the equipment.
The amount of compressor oil removed must be measured and
the same amount added to the system.

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 1B-10 AIR CONDITIONING (OPTIONAL)

4) Disconnect suction pipe, and liquid pipe from evaporator (cool-

ing unit).
NOTE:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust may not enter
cooling unit.
5) Remove blower motor unit. Refer to Section 1A “HEATER AND
1. Suction pipe VENTILATION”.
2. Liquid pipe
6) Disconnect thermistor wire coupler.
7) Remove evaporator with evaporator case.

LH steering vehicle DISASSEMBLY

1) Remove filter assembly (if equipped).

1. Cover
2. Filter
3. Evaporator assembly

2) Remove screws to separate evaporator upper and lower cases

LH steering vehicle
from each other.

1. Screw

LH steering vehicle 3) Remove upper case and remove evaporator from lower case.
1
4) Remove following components from evaporator.

Expansion valve

Thermistor

1. Upper case
2. Evaporator
3. Lower case
4. Thermistor
5. Expansion valve

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 AIR CONDITIONING (OPTIONAL) 1B-11

INSPECTION
1) Check evaporator fins for blockage. If found clogged, use com-
pressed air to clean the fins.

NOTE:
Do not use water for cleaning of evaporator.

2) Check inlet and outlet fittings for crack or scratch. Repair them
as required.

ASSEMBLY AND INSTALLATION

1) Reverse removal sequence to install evaporator.
2) Enable air bag system. Refer to “Enabling Air Bag System” in
Section 10B.
3) Evacuate and charge system according to previously described
procedure.

EXPANSION VALVE
INSPECTION
Refer to “Troubleshooting Procedure Using Manifold Gauge Set” in
this section.
REMOVAL
1) Recover refrigerant by using recovery and recycling equipment.
Be sure to follow the instruction manual for the equipment. The
amount of compressor oil removed must be measured and the
same amount added to the system.
2) Remove front grill.
3) Disconnect suction pipe, and liquid pipe from evaporator (Cool-
ing unit).

NOTE:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust may not enter
cooling unit.

1. Suction pipe
2. Liquid pipe

4) Disconnect suction pipe, and liquid pipe from suction hose and
condenser outlet pipe.
5) Remove pipe clamp then remove suction pipe and liquid pipe.

1. Suction hose
2. Condenser outlet pipe
3. Pipe clamp

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 1B-12 AIR CONDITIONING (OPTIONAL)

6) Remove expansion valve.

1. Expansion valve

INSTALLATION
1) Reverse removal sequence to install expansion valve.
2) Evacuate and charge system according to previously described
procedure.

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 AIR CONDITIONING (OPTIONAL) 1B-13

G16 LH steering vehicle

COMPRESSION SYSTEM
COMPRESSOR
INSPECTION
1) Install manifold gauge set as illustrated.
2) Close Hi and Lo hand valves.
3) Run engine at fast idle.
4) Check compressor for following:
a. High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.
b. Metallic sound.
c. Leakage from shaft seal.
If any of the above checks indicated a defect, repair compressor.

1. Manifold gauge set

2. High pressure side
(Delivery side hose)
3. Low pressure side
(Suction side pipe)

REMOVAL
1) Run engine at idle with A/C ON for 10 minutes.
2) Disconnect negative cable at battery.
3) Recover refrigerant from refrigeration system using recovery
and recycling equipment.

NOTE:
The amount of compressor at removed must be measured
and the same amount must be poured when installing the
compressor.

4) Disconnect thermal protector lead wire.

5) Disconnect suction and discharge hoses from compressor.

NOTE:
Cap open fitting immediately to keep moisture out of sys-
tem.

6) For G16 engine:

Remove compressor drive belt by loosening compressor
mounting bolts.
For J20 engine:
Remove generator belt. Refer to Section 6H for details.
7) Remove compressor with clutch assy from its mount.
8) Drain oil from compressor, and measure its amount.

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 1B-14 AIR CONDITIONING (OPTIONAL)

INSTALLATION
G16 engine
1) Pour new compressor oil. The amount must be the same with
the amount measured in REMOVAL.
(b)
NOTE:
Compressor assembly supplied from factory is filled up
with following amount of oil.

Amount of oil in compressor: 120 cm3 (120 cc, 7.5 in3)

2) For G16 engine:

Install compressor temporarily to bracket, then install compres-
sor drive belt.

For J20 engine:

Install compressor to its bracket.
Tighten bolts (a) first, then (b).

Tightening Torque
(a), (b): 23 N.m (2.3 kg-m, 17.0 lb-ft)

3) Connect suction and discharge hoses to compressor.

J20 engine
4) For G16 engine:
Tension compressor drive belt by tightening compressor mount-
ing bolts. Refer to Section 3B1 for drive belt tension.
Tighten bolt (a) first, then (b).

Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

For J20 engine:

Install generator belt. Refer to Section 6H for details.
5) Connect thermal protector lead wire.
6) Evacuate and charge system according to previously described
procedure.

CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.

1. Generator belt 3. Compressor pulley

2. Compressor drive belt 4. Crankshaft pulley

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 AIR CONDITIONING (OPTIONAL) 1B-15

MAGNET CLUTCH

1. Armature plate bolt

2. Armature plate
3. Circlip
4. Magnet clutch
5. Shim
6. Magnet clutch coil
7. Compressor body assembly

INSPECTION
a. Inspect pressure plate and rotor for signs of oil.
b. Check clutch bearings for noise and grease leakage.
c. Using and ohmmeter, measure resistance of stator coil between
clutch lead wire and ground.
If measured resistance is not within tolerance, replace coil.

Standard resistance: 3.9 – 4.3
at 20 _C, 68 _F

REMOVAL
1) Remove compressor from vehicle. Refer to COMPRESSOR in
this section.
2) Fix armature plate with special tool (A) and remove armature
plate bolt and washer.
Special Tool
(A): 09991-06020
NOTE:
1. Armature plate
Do not reuse armature plate bolt.

3) Using special tool (B), remove armature plate.

Special Tool
(B): 09991-06030

1. Armature plate

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 1B-16 AIR CONDITIONING (OPTIONAL)

4) Remove shims from shaft.

5) Using special tool (C), remove circlip.

Special Tool
(C): 09900-06107

6) Remove magnet clutch lead wire clamp screw, and remove

magnet clutch read wire ground terminal.

7) Remove magnet clutch with puller.

NOTE:
Be careful not to damage pulley when tapping magnet
clutch.

1. Puller
2. Compressor

8) Remove magnet clutch coil.

Special tool
(C): 09900-06107

INSTALLATION
1) Install magnet clutch coil.
Protrusion on under side of coil ring must match hole in com-
pressor assembly to prevent movement ant correctly locate lead
wire.
2) Using special tool (C), install snap ring as shown.

1. Snap ring
Special Tool
2. Clutch coil (C): 09990-06107
3. Compressor
assembly
3) Install clamp portion and ground terminal of lead wire.

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 AIR CONDITIONING (OPTIONAL) 1B-17

4) Install magnet clutch.

(1) Set magnet clutch squarely over clutch installation boss.
(2) Place special tool (D) onto clutch bearing.
Ensure that edge rests only on inner race of bearing.
(3) Install snap ring.

Special Tool
(D): 09991-06010

CAUTION:
Be careful not to scratch bearing seal.

5) Adjust clearance, between armature plate and magnet clutch by

putting shim on compressor shaft.

Standard clearance “a”: 0.3 – 0.5 mm (0.012 – 0.02 in.)

“a”

6) Tighten new armature plate nut as specified below.

Tightening Torque
(a): 14 N.m (1.4 kg-m, 10.5 lb-ft)

Special Tool
(A): 09991-06020

1. Armature plate

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 1B-18 AIR CONDITIONING (OPTIONAL)

SPECIAL TOOLS

09900-06107
Snap ring pliers 09991-06010 09991-06020 09991-06030
(Opening type) Magnet clutch pulley installer Armature plate spanner Armature plate remover

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 POWER STEERING (P / S) SYSTEM 3B1-1

SECTION 3B1

POWER STEERING (P/S) SYSTEM

3B1
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

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.

Power Steering Gear Box cannot be disassembled or adjusted.

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 replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B1- 2

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B1- 3
Rack Boot/Tie-rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B1- 3
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B1- 5
TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B1- 6
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B1- 6

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 3B1-2 POWER STEERING (P / S) SYSTEM

GENERAL DESCRIPTION
The power steering (P/S) system in this vehicle reduces the driver’s effort needed in turning the steering wheel
by utilizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine.
It is an integral type with the rack and pinion gears and the control valve unit, hydraulic pressure cylinder unit all
built in the steering gear box.

1. Power steering gear box

2. Power steering pump
3. Oil tank

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 POWER STEERING (P / S) SYSTEM 3B1-3

ON-VEHICLE SERVICE
RACK BOOT/TIE-ROD
(LH STEERING VEHICLE)
REMOVAL
1) Remove steering gear case, refer to POWER STEERING
GEAR BOX ASSEMBLY REMOVAL.
1. Tie-rod
2. Steering rack 2) For ease of adjustment after installation, make marking of tie-rod
3. Boot
4. Mark
end lock nut position of tie-rod thread.
3) Loosen tie-rod end lock nut and remove tie-rod end.
4) Remove boot band and clip.
5) Remove boot from tie-rod.

6) Unbend washer (2 places), and remove tie-rod from rack.

1. Tie-rod lock washer

2. Tie-rod
3. Steering rack
4. Aluminium plate
5. Vise

INSTALLATION
1) Install new tie-rod lock washer and tie-rod to rack.
2) Tighten tie-rod ball nut to specified torque.

Tightening Torque
(a): 85 N.m (8.5 kg-m, 61.5 lb-ft)

3) Bend lock washer 2 place at the flat part of tie-rod ball nut.

1. Tie-rod lock washer 1

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 3B1-4 POWER STEERING (P / S) SYSTEM

4) Apply grease to “A” indicated in figure.

5) Position boot properly in grooves of gear case and tie-rod.
Check to ensure that boot is free from twist and dent.

6) Fasten boot with new clamp and clip securely.

Special Tool
(A): 09943-55010

(A)

7) Install tie-rod end lock nut and tie-rod end to tie-rod.

Position lock nut to marking made in removal.
“A”

NOTE:
When tie-rod was replaced, measure length “A” on re-
moved tie-rod and use it on new replacement tie-rod so as
to position lock nut properly.

1 8) Install steering gear case. Refer to POWER STEERING GEAR

1. Mark
BOX ASSEMBLY INSTALLATION in this section.

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 POWER STEERING (P / S) SYSTEM 3B1-5

POWER STEERING PUMP

[A] Tightening Torque

(a): 60 N.m (6.0 kg-m, 43.5 lb-ft)
(b):25 N.m (2.5 kg-m, 18.5 lb-ft)
(c): 55 N.m (5.5 kg-m, 40.0 lb-ft)
(e): 35 N.m (3.5 kg-m, 25.5 lb-ft)
(f): 40 N.m (4.0 kg-m, 29.0 lb-ft)

[B]

[A]: G16 Type engine

[B]: J20 Type engine

1. Power steering pump assembly 4. High pressure hose & pipe 6. Low pressure return hose
2. Bracket 5. Suction hose 7. Oil tank bracket
3. Power steering oil tank

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 3B1-6 POWER STEERING (P / S) SYSTEM

TIGHTENING TORQUE SPECIFICATIONS

Tightening torque
Fastening parts
arts
N.m kg-m lb-ft
G16 Type engine 55 5.5 40.0
Pump bracket bolt
J20 Type engine 25 2.5 18.5
Tie-rod (LH steering vehicle) 85 8.5 61.5

SPECIAL TOOL

09943-55010
Boot clamp plier

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 AIR BAG STEERING WHEEL AND COLUMN 3C1-1

SECTION 3C1

AIR BAG STEERING WHEEL AND COLUMN

3C1
WARNING:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. 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 compo-
nents 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.

The procedures in this section must be followed in the order listed to disable the air bag system tem-
porarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could
result in possible activation of the air bag system, personal injury or otherwise unneeded air bag sys-
tem repairs.

CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called
out. The correct torque value must be used when installing fasteners that require it. If the above proce-
dures are not followed, parts or system damage could result.

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C1- 2

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C1- 3
Driver air bag (inflator) module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C1- 3

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 3C1-2 AIR BAG STEERING WHEEL AND COLUMN

GENERAL DESCRIPTION

1. Driver air bag (inflator) module 8. Steering lock assembly

2. Steering wheel 9. Steering column hole cover
3. Steering wheel nut 10. Steering shaft joint
4. Contact coil and combination switch assembly 11. Steering lower shaft assembly
5. Steering column upper cover 12. Adjustable steering column release lever
6. Steering column lower cover 13. Steering column lower seal
7. Steering column assembly 14. Cap

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 AIR BAG STEERING WHEEL AND COLUMN 3C1-3

ON-VEHICLE SERVICE
DRIVER AIR BAG (INFLATOR) MODULE
WARNING:
When handling an air bag (inflator) module, be sure to read
“Service Precautions” under “On-Vehicle Service” in SEC-
TION 10B and observe each instruction. Failure to follow
them could cause a damage to the air bag (inflator) module
or result in personal injury.

REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to “Disabling Air Bag System” un-
der “Service Precautions” in SECTION 10B.

3) Remove mounting bolt hole caps (2pcs).

4) Loosen 2 bolts mounting driver air bag (inflator) module till it
turns freely, pull them out and fix them to bolt clamps.
5) Remove air bag (inflator) module from steering wheel.

1 1

1. Mounting bolt

6) Remove driver air bag (inflator) module (yellow) connector and

horn connector from steering wheel.
7) Disconnect driver air bag (inflator) module (yellow) connector of
driver air bag (inflator) module and horn connector as shown in
the figure.
ii) Release locking of lever.
ii) After unlocked, disconnect connector.

WARNING:
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) module. Observe
“Service Precautions” under “On-Vehicle Service” in
SECTION 10B. Otherwise, personal injury may result.

1. Driver air bag (inflator) module connector

2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel

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 3C1-4 AIR BAG STEERING WHEEL AND COLUMN

INSPECTION

WARNING:
Never disassemble air bag (inflator) module or measure its
resistance. Otherwise, personal injury may result.

CAUTION:
If air bag (inflator) module was dropped from a height of 90
cm (3 ft) or more, it should be replaced.

Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.

Air bag being deployed

Trim cover (pad surface) being cracked

Wire harness or connector being damaged

Air bag (inflator) module being damaged or having been exposed
to strong impact (dropped)

1. Trim cover (pad surface)

2. Inflator case
3. Wire harness

INSTALLATION
1) Connect horn connector securely.
2) Connect yellow connector of driver air bag (inflator) module con-
nector as shown in the figure securely.
ii) Connect connector.
ii) Lock connector with lock lever.
3) Install horn connector and driver air bag (inflator) module con-
nector.
4) Install driver air bag (inflator) module to steering wheel, taking
care so that no part of wire harness is caught between them.
5) Make sure that clearance between module and steering wheel
is uniform all the way.
6) Tighten driver air bag (inflator) module mounting bolt (left side)
to specified torque first and then driver air bag (inflator) module
mounting bolt (right side) to specified torque.

Tightening Torque
(a): 9 N.m (0.9 kg-m, 6.5 lb-ft)

7) Install mounting bolt hole caps (2 pcs).

8) Connect negative battery cable.
9) Enable air bag system. Refer to “Enabling Air Bag System” un-
der “Service Precautions” in SECTION 10B.

6, (a)

1. Driver air bag (inflator) module connector

2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel
5. Mounting bolt (left side)
6. Mounting bolt (right side)

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 FRONT SUSPENSION 3D-1

SECTION 3D

FRONT SUSPENSION
CAUTION:

All front suspension fasteners are an important attaching part in that it could affect the performance

3D
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.

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D- 2

Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D- 2
Knuckle/Wheel Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D- 6
TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D- 9

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 3D-2 FRONT SUSPENSION

ON-VEHICLE SERVICE
COIL SPRING
REMOVAL
1) Hoist vehicle, allowing front suspension to hang free.
2) Remove wheels.
3) Remove axle shaft drive flange.

4) Remove front drive shaft circlip and washer.

1. Circlip
2. Washer

5) Remove caliper bolts and suspend caliper with a wire hook.

CAUTION:
Hang removed caliper with a wire hook so as to prevent
brake hose from bending and twisting excessively or be-
ing pulled.
Don’t operate brake pedal with pads removed.

1. Wire

6) If equipped with ABS, remove harness clamp bolt and remove

front wheel speed sensor from knuckle.

CAUTION:

Do not pull wire harness when removing front wheel
speed sensor.

Do not cause damage to surface of front wheel speed
1. Front wheel
sensor and do not allow dust, etc. to enter its installa-
speed sensor tion hole.
2. Harness clamp bolt

7) Remove brake disc.

NOTE:
If brake disc can not be removed by hand, use 8 mm bolts
as shown.

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 FRONT SUSPENSION 3D-3

8) Remove stabilizer bar, refer to steps 2) to 5) of item STABILIZ-

ER BAR/BUSHINGS REMOVAL in this section.
9) Disconnect tie rod end from knuckle by using puller.

10) Support lower arm, using jack as shown.

11) Remove strut bracket bolts.

12) Remove ball stud nut.

13) Using puller, disconnect knuckle from ball stud.

14) Remove knuckle and wheel hub comp, while lowering jack.
15) Remove coil spring.

1. Coil spring

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 3D-4 FRONT SUSPENSION

INSTALLATION
Reverse removal procedure to install coil spring.

NOTE:
Upper and lower diameters of coil spring are different.
Bring larger diameter end at bottom and set its open end in
place on spring seat.

1. Spring seat “a” < “b”

Be sure to use specified torque for tightening each fastener.

Refer to torque specification chart at the end of this section.

As for ball stud nut, be sure to use new nut.

Tighten tie-rod end nut with pushing ball stud to upper side so as
not ball stud to be rotated.

Apply lithium grease to front drive shaft washer and front wheel
spindle outer.

“A”: Grease 99000-25010

“A”

When installing circlip to drive shaft, utilize screw hole in drive

shaft to pull it out and bring large diameter of circlip at right as
shown.

1. Circlip
2. Large diameter

When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange and tighten flange bolt
to specified torque.

“A”: Sealant 99000-31090

2, (a)
Tightening Torque
(a): 48 N.m (4.8 kg-m, 35.0 lb-ft)

1. Axle shaft drive flange

2. Bolt

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 FRONT SUSPENSION 3D-5

Check that no foreign material is attached to sensor and rotor.

Install wheel speed sensor and its harness clamp.
2, (b)
Tightening Torque
(a): 10 N.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
1

CAUTION:

Do not pull wire harness or twist more than necessary
when installing front wheel speed sensor.

Fit harness grommet to inner fender securely.
1. Front wheel speed sensor
2. Bolt

Check that there is no clearance between sensor and knuckle.

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 3D-6 FRONT SUSPENSION

KNUCKLE/WHEEL SPINDLE
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange, drive shaft circlip and washer.
Refer to steps 3) to 4) of item COIL SPRING REMOVAL in this
section.
3) Remove wheel hub. Refer to steps 3) to 9) of item WHEEL
HUB/BEARING/OIL SEAL REMOVAL in this section.
4) Disconnect tie-rod end from knuckle.

5) Remove ball stud nut.

6) Support lower arm with jack.
7) Remove strut bracket bolts from strut bracket.

1. Strut
2. Knuckle

8) By using puller, disconnect knuckle from ball stud.

9) While lowering jack, remove knuckle/wheel spindle comp.

10) Remove inner oil seal, dust cover and wheel spindle.

1. Dust cover
2. Wheel spindle
3. Knuckle
4. Inner oil seal

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 FRONT SUSPENSION 3D-7

11) Remove drive shaft bearing by using special tool.

Special Tool
(A): 09923-74510
(B): 09930-30102

1. Wheel spindle
2. Drive shaft bearing

INSTALLATION
Reverse removal sequence to install knuckle, wheel spindle oil seal
and drive shaft bearing,noting following points.

Install front drive shaft thrust washer with its chanfered side facing
to drive shaft side.
1. Wheel spindle
2. Drive shaft
bearing
3. Front drive
shaft thrust
washer
4. Inner oil seal

Install drive shaft bearing by using special tool.

Special Tool
(A): 09913-80112

Depth “a”: 1.75 – 2.50 mm (0.069 – 0.098 in.)

1. Drive shaft bearing

2. Wheel spindle

NOTE:

When installing wheel spindle to knuckle, coat their mating
surfaces with sealant.
“A”
“A”: Sealant 99000-31110

Also, fill recess in wheel spindle with about 10 g lithium

grease.
“B”
“B”: Grease 99000-25010

Tighten wheel spindle nut to specified torque.

Tightening Torque
(a): 50 N.m (5.0 kg-m, 36.5 lb-ft)

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 3D-8 FRONT SUSPENSION

Press-fitting inner oil seal.

Drive in inner oil seal until its end contacts stepped surface of
knuckle using special tools.

Special Tool
(B): 09944-66010
(C): 09924-74510

Apply lithium grease to oil seal lip and into its hollow to fill more
than 60% of its vacant space.

“B”: Grease 99000-25010

Press-fit front drive shaft thrust washer to drive shaft, if it is re-

moved.

1. Thrust washer

Tighten control arm ball stud nut.

When tightening ball stud nut, use new nut and tighten it to speci-
fied torque.

Tightening Torque
(a): 60 N.m (6.0 kg-m, 43.5 lb-ft)

(a)

When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.

“A”: Sealant 99000-31090

Tightening Torque
(a): 48 N.m (4.8 kg-m, 35.0 lb-ft)

For installation procedures following the above, refer to WHEEL

HUB/BEARING/OIL SEAL INSTALLATION of this section.

Tightening torque.
For any tightening torque other than those specified in text, refer
to torque specification table at the end of this section.

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 FRONT SUSPENSION 3D-9

TIGHTENING TORQUE SPECIFICATIONS

[D]

[A] [C]

48 N.m

60 N.m

[B]

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 REAR SUSPENSION 3E-1

SECTION 3E

REAR SUSPENSION
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 replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-

3E
sembly to assure proper retention of this part.

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

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

CONTENTS

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E- 2

Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E- 2
Lower Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E- 3
Rear Axle Shaft Inner Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E- 4
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E- 4

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 3E-2 REAR SUSPENSION

ON-VEHICLE SERVICE
SHOCK ABSORBER
The shock absorber is non-adjustable, non-refillable, and cannot
be disassembled. The only service the shock absorber requires is
replacement when it has lost its resistance, is damaged, or leaking
fluid.

REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack to prevent it from
lowering.

1. Rear axle housing

2. Floor jack

3) Remove absorber nut.

4) Remove lower mounting bolt.
5) Remove shock absorber.

1. Blank
2. Absorber nut
3. Upper support
4. Rubber bush
5. Lower support
6. Shock absorber
7. Bolt

Upper side INSTALLATION

1) Install shock absorber. Refer to figure for proper installing direc-
tion of lower mounting bolt.
2) Remove floor jack.
3) Lower hoist.
4) Tighten nuts to specified torque.

NOTE:

Tighten lower nut with vehicle off hoist and in non-loaded
condition.

Use new absorber nut.
Lower side
Tightening Torque
(a): 29 N.m (2.9 kg-m, 21.0 lb-ft)
(b): 85 N.m (8.5 kg-m. 61.5 lb-ft)

* Body Outside

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 REAR SUSPENSION 3E-3

LOWER ROD
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack.

1. Axle housing
2. Floor jack

3) Remove lower rod front mount bolt.

1. Lower rod
2. Front mount bolt

4) Remove lower rod rear mount bolt.

1. Lower rod
2. Rear mount nut

INSTALLATION
Body side Axle side 1) Install lower rod to chassis frame and axle housing, referring to
figure for proper installing direction of bolts.

Nuts should not be tightened.

1. Lower rod
2. Front bolt
2) Remove floor jack from rear axle housing.
3. Rear bolt 3) Install wheel and tighten wheel nuts to specified torque.
4. Vehicle body
5. Axle housing
6. Body center Tightening Torque for wheel nuts
7. Body out side
95 N.m (9.5 kg-m, 69.0 lb-ft)

4) Lower hoist and with vehicle in non loaded condition, tighten

front bolts and rear bolts and nuts of lower rod to specified
torque.

Tightening Torque
(a): 90 N.m (9.0 kg-m, 65.0 lb-ft)

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 3E-4 REAR SUSPENSION

REAR AXLE SHAFT INNER OIL SEAL

REMOVAL
1) Remove rear axle shaft. For details, refer to steps 1) to 7) of
REAR AXLE SHAFT REMOVAL in this section.
2) Fix brake back plate by inserting screwdriver to the hole for bear-
ing retainer mounting.
3) Remove rear axle shaft inner oil seal.

1. Inner oil seal NOTE:

2. Axle housing
Take care not to bend the brake pipe.
INSTALLATION
1) Using special tool drive in oil seal until it contacts oil seal protec-
tor in axle housing.

NOTE:

Make sure that oil seal is free from inclination as it is
installed.
*
Refer to figure so that oil seal is installed in proper direc-
tion.

Special Tool
(A): 09913-75510
“A”: Grease 99000-25010

2) For procedure hereafter, refer to steps 6) to 11) of REAR AXLE

SHAFT INSTALLATION in this section.

* Body center
1. Oil seal protector
2. Oil seal

SPECIAL TOOL

09913-75510
Oil seal installer

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

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

3F
mentioned in FOREWORD of this manual.

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F- 1

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F- 1
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F- 1
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F- 2
Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F- 2

GENERAL DESCRIPTION
TIRES
This vehicle is equipped with following tire, depending on vehicle specification.
P205/75 R15 (1.6
) or P215/65 R16 (2.0
)
The tires are of tubeless type. The tires are designed to operate satisfactorily with loads up to the full rated load
capacity when inflated to the recommended inflation pressure.
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.

WHEELS
Standard equipment wheels are following steel wheels.
15 x 5 1/2 JJ (1.6
) or 16 x 6 1/2 J (2.0
)

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 3F-2 WHEELS AND TIRES

ON-VEHICLE SERVICE
TIRE
MOUNTING AND DEMOUNTING
Use tire changing machine to mount or demount tires. Follow equip-
ment manufacturer’s instructions. Do not use hand tools or tire
irons alone to change tires as they may damage tire beads or wheel
rim.
Rim bead seats should be cleaned with wire brush or coarse steel
wool to remove lubricants, old rubber and light rust. Before mount-
ing or demounting tire, bead area should be well lubricated with ap-
proved tire lubricant.
After mounting, inflate to 240 kPa (35 psi) so that beads are com-
pletely seated.
Then adjust pressure to specified shown on tire placard.

WARNING:
Do not stand over tire when inflating. Bead may break when
bead snaps over rim’s safety hump and cause serious per-
sonal injury.
Do not exceed 240 kPa (35 psi) pressure when inflating. If
240 kPa (35 psi) pressure will not seat beads, deflate, re-lu-
bricate and reinflate. Over inflation may cause bead to break
and cause serious personal injury.

Install valve core and inflate to proper pressure.

TIRE REPAIR
There are many different materials and techniques on the market
to repair tires. As not all of these work on all types of tires, tire
manufacturers have published detailed instructions on how and
when to repair tires. These instructions can be obtained from the
tire manufacturer.

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 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-1

SECTION 4A2

FRONT DRIVE SHAFT/SHAFT BEARING,

OIL SEAL
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

4A2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2- 2
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2- 2

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 4A2-2 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL

ON-VEHICLE SERVICE
DRIVE SHAFT
REMOVAL (LEFT SIDE)
1) Hoist vehicle and remove wheel.

1. Oil filler / level plug

2. Front drain plug

2) Remove axle shaft drive flange.

3) Remove drive shaft circlip and washer.

1. Circlip
2. Washer

4) Remove drive shaft flange bolts and nuts.

1. Drive shaft flange

bolts and nuts

5) Remove drive shaft assembly to differential side as shown in left

figure.

CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.

6) Remove drive shaft thrust washer from drive shaft and remove
drive shaft oil seal as shown in figure.

CAUTION:
Be careful not to cause damage to drive shaft joint.

1. Oil seal

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 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3

REMOVAL (RIGHT SIDE)

1) Hoist vehicle and remove wheel.
2) Drain differential gear oil.

1. Oil filler / level plug

2. Front drain plug

3) Remove axle shaft drive flange.

4) Remove drive shaft circlip and washer.
5) Remove knuckle and wheel hub comp, refer to steps 5) to 7) and
9) to 14) of item COIL SPRING REMOVAL in Section 3D.
2

1. Circlip
2. Washer

6) Remove drive shaft assembly.

To detach snap ring fitted on the spline of differential side joint
(inboard joint) from differential side gear, pull inboard joint by us-
ing a tire lever.

CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.

1. Differential side joint

2. Tire lever
3. Front differential assembly

7) Remove drive shaft thrust washer from drive shaft and remove
drive shaft oil seal as shown in figure.

CAUTION:
Be careful not to cause damage to drive shaft joint.

1. Oil seal

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 4A2-4 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL

DISASSEMBLY
1) Remove boot band of differential side joint.

2) Slide boot toward the center of shaft and remove snap ring from
outer race, then take shaft out of outer race.

1. Boot
2. Snap ring

3) Remove circlip and then cage.

4) Remove inside and outside boots from shaft.

CAUTION:

Do not disassemble wheel side joint (outboard joint). If
any malcondition is found in joint, replace it as assem-
bly.

Do not disassemble ball joint of differential side joint.
1. Circlip
2. Snap ring plier
If any malcondition is found in ball joint, replace differ-
3. Cage ential side joint assembly.

INSPECTION

Check boots for breakage or deterioration. Replace them as nec-
essary.

Check circlip, snap ring and boot bands for breakage or deforma-
tion. Replace as necessary.

CLEANING

Wash disassembled parts (except boots) in degreaser. After
washing, dry parts completely by blowing air.

Clean boots with cloth. DO NOT wash boots in degreaser, such
as gasoline or kerosene, etc..
Washing in degreaser causes deterioration of boot.

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 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-5

ASSEMBLY
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part or joint grease
(99000-25120).
2) Fit wheel side boot on shaft.
Fill up inside of boot with joint grease of about 85 gram.
Before fixing boot band, insert screwdriver into boot on joint side
and allow air to enter boot so that air pressure in boot becomes
the same as atmospheric pressure.
3) Fixing boot band.
4) Install boot onto drive shaft till its small diameter side fits to shaft
groove and fix there with boot band.

1. Boot
2. Boot band

5) Install cage to shaft.

CAUTION:
Install cage directing smaller outside diameter side to
shaft end.

1. Cage

6) Install circlip by using snap ring plier.

1. Circlip

7) Apply grease to entire surface of cage.

Use joint grease in tube included in spare part or joint grease
(99000-25120).

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 4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL

8) Insert cage into outer race and fit circlip into groove of outer
race.

CAUTION:
Position opening of circlip “a” so that it will not be lined
up with a ball.

1. Circlip

9) Apply grease to inside of outer race, and fit boot to outer race.
Fill up inside of boot with joint grease.

“A”: Joint Grease 99000-25120

10) Fitting boot to outer race, adjust so that measurements “b” and
“c” become as indicated in figure.

Length “b”: 203.2 – 213.2 mm (8.00 – 8.40 in.)

Length “c”: 125.5 – 135.5 mm (4.94 – 5.33 in.)

Before fixing boot band, insert screwdriver into boot on joint

side and allow air to enter boot so that air pressure in boot be-
comes the same as atmospheric pressure.
11) Clamp boot band. Check boots for distortion or dent.

“A”: Fill grease 85 g (3.0 oz)

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 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-7

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

Clean front drive shaft oil seal and then apply lithium grease to oil
seal and DOJ shaft.

“A”: Grease 99000-25010

Check oil seal for breakage or deterioration.

1. Drive shaft oil seal
Replace it as necessary.

Drive in oil seal until its end contacts stopped surface of drive
shaft joint by using a pipe whose inner diameter is 76 mm (2.992
in.) or more and outer diameter is 80 mm (3.150 in.) or less.

Diameter “a”: 76 mm (2.992 in.) or more

Diameter “b”: 80 mm (3.150 in.) or less

Drive in drive shaft thrust washer.

1. Drive shaft joint
2. Oil seal
3. Pipe
4. Thrust washer

RH Side
Push differential side joint by hand until it is positioned by snap
ring fitted to its spline.

LH Side
Connect drive shaft flange bolts and nuts.

Tightening Torque
(a): 50 N.m (5.0 kg-m, 36.5 lb-ft)

When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.

“A”: Sealant 99000-31090

Tightening Torque
(b): 48 N.m (4.8 kg-m, 35.0 lb-ft)

CAUTION:

To prevent breakage of boots (wheel side and differen-
tial side), be careful not to bring them into contact with
other parts when installing drive shaft assembly.

Do not pull housing of differential side joint.
If housing is pulled, it may be detached from drive shaft.

Apply chassis grease to spline of sliding yoke.

2, (b)

Fill specified differential gear oil into differential case to specified
level.

1. Drive shaft flange bolt and nut

2. Axle shaft drive flange

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 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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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

5
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

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

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

CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 2

Fluid Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 2
TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 3

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 5-2 BRAKES

CHECK AND ADJUSTMENT

FLUID PRESSURE TEST(if equipped with
LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.
1) Stop vehicle on level floor and place approximately about 200
kg (441 lbs) weight on rear housing so that rear axle weighs 800
kg (1764 lb).

Rear axle weight “L”: 800 kg (1764 lb)

2) Install special tool to front and rear brake.
NOTE:
Special tool should be connected to breather of front (driv-
er’s side brake) and rear brakes.
Special Tool
2
Front brake
(A): 09956-02310
“L”
(C): 55473-82030 (Air bleeder plug supplied as a spare part)
Rear brake
(A): 09956-02310
(B): 09952-36310
(C): 55473-82030 (Air bleeder plug supplied as a spare part)
NOTE:
Special tool (B) is used instead of thread diameter 10 mm
1. Air bleeder plug
attachment of special tool (A).
2. Weight So remove the attachment from (A) and install (B) as shown
3. Attachment
in figure.

3) Depress brake pedal gradually till fluid pressure of front brake

becomes as specified below and check corresponding pressure
of rear brake then. It should be within specification given below.

Front brake Rear brake

8,000 kPa 6,000 – 7,300 kPa
80 kg/cm2 60 – 73 kg/cm2
1,138 psi 853 – 1,038 psi

As done above, apply 100 kg/cm2 pressure to front brake and

check that rear brake pressure then is within specification as giv-
en below.

Front brake Rear brake

10,000 kPa 6,500 – 8,000 kPa
100 kg/cm2 65 – 80 kg/cm2
1,422 psi 924 – 1,138 psi

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 BRAKES 5-3

4) If rear brake pressure is not within specification, adjust it by

2 changing stay “A” position as follows.
1
Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
“b”
3, “A”
If rear brake pressure is higher than specification, move stay
“A” to direction “a” and if it is lower, to direction “b”.
“a”

Repeat steps 3) and 4) until rear brake pressure is within spec-
1. LSPV lever (a) ification.
2. LSPV spring 3. LSPV stay

After adjustment, be sure to torque nut to specification.
5) Disconnect brake pipe (connecting between master cylinder
secondary side and 4-way joint) from master cylinder.
Tighten plug (special tool) to master cylinder.
Depress brake pedal. If rear brake pressure is 95 – 100 kg/cm2
when front brake pressure is 100 kg/cm2, it means that front fail-
safe system functions properly.

Front brake Rear brake

10000 kPa 9500 – 10000 kPa
100 kg/cm2 95 – 100 kg/cm2
3 1422 psi 1350 – 1422 psi
2
Special Tool
(A): 09956-02210

1. Master cylinder
2. Disconnect brake pipe (for LH steering vehicle)
3. Disconnect brake pipe (for RH steering vehicle)

6) Upon completion of fluid pressure test, bleed brake system and

perform brake test.

TIGHTENING TORQUE SPECIFICATIONS

Tightening torque
Fastening parts
arts
N.m kg-m lb-ft
LSPV mounting bolt
23 23
2.3 17 0
17.0
LSPV stay bolt

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 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 autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

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

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

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A- 2

LSPV (Load Sensing Proportioning Valve) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A- 2
TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A- 4

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 5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER

ON-VEHICLE SERVICE
LSPV (Load Sensing Proportioning Valve)
ASSEMBLY (if equipped)
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Hoist vehicle.
1. LSPV 3) Disconnect brake pipes from LSPV.
2. Brake pipe

4) Remove LSPV assembly from vehicle body.

NOTE:
As shown in figure left, LSPV assembly should be removed
together with its spring and stay installed or rear axle hous-
ing.

5) Remove spring and stay from lever.

CAUTION:

LSPV assembly must not be disassembled.
Replace with new one if defective.

Stopper bolt should not be loosened or tightened.

1. LSPV assembly
2. LSPV spring
3. LSPV stay
4. Bolt

INSTALLATION

CAUTION:
Refer to above CAUTION.

Install by reversing removal procedure, noting the following.

1) Apply multi-purpose grease to upper and lower joint of coil
spring.

“A”: Apply grease

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 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3

2) Torque each bolt and nut to specification as indicated respec-

tively in figure left.

Tightening Torque
1, (a)
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
(b): 16 N.m (1.6 kg-m, 11.5 lb-ft) (brake flare nut)
(c): 7.5 N.m (0.75 kg-m, 9.0 lb-ft) (bleeder plug)

3) Upon completion of installation, fill reservoir tank with specified

1. LSPV stay bolt
fluid and bleed air from brake system.
2. LSPV bolt
3. Brake pipe flare nut NOTE:
4. Air bleeding plug
Make sure to bleed air from LSPV bleeder without failure.

4) After bleeding air, check that LSPV is installed properly, referring

to following INSPECTION & ADJUSTMENT.

INSPECTION & ADJUSTMENT

Confirm the following before inspection and adjustment.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.

Vehicle is free from any other load.

With vehicle in above conditions;

1) Place it on level floor.
2) Push up LSPV lever with finger till it stops and measure length
of coil spring (“L” in below figure) as it is pulled.
3) Spring length “L” should be the value specified below.

Spring length (between spring ends)

“L”: 103 mm (4.06 in.)

4) If it isn’t, adjust it to specification by changing stay positions as

shown in left figure. After adjustment, tighten bolt to specified
torque.
For details, refer to left figure.
Tightening Torque
(a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
NOTE:
1. LSPV stay bolt Check to make sure that LSPV body and brake pipe joints
2. LSPV stay
are free from fluid leakage. Replace defective parts, if any.

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 5A-4 BRAKES PIPE / HOSE / MASTER CYLINDER

TIGHTENING TORQUE SPECIFICATIONS

Tightening torque
Fastening parts
arts
N.m kg-m lb-ft
LSPV mounting bolt
23 23
2.3 17 0
17.0
LSPV stay bolt

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 ENGINE GENERAL INFORMATION (G16 / J20 / H25 ENGINE) 6-1

SECTION 6

ENGINE
(G16/J20/H25 ENGINE)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

6
NOTE:
For the description (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 2
General Information on Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 2
Fuel pressure relief procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 2

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 6-2 ENGINE GENERAL INFORMATION (G16 / J20 / H25 ENGINE)

Left hand steering vehicle

GENERAL INFORMATION
GENERAL INFORMATION ON ENGINE
SERVICE
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.

After making sure that engine is cold, relief fuel pressure as follows.
1) Place transmission gear shift lever in “Neutral” (shift selector le-
1. Fuel pump relay ver to “P” range for A/T vehicle), set parking brake, and block
2. Junction (Fuse) box
drive wheels.
2) Remove fuel pump relay from connector.
3) Remove fuel filler cap to release fuel vapor pressure in fuel tank
Right hand steering vehicle
and then reinstall it.
4) Start engine and run it till it stops for lack of fuel. Repeat cranking
engine 2 – 3 times of about 3 seconds each time to dissipate fuel
pressure in lines. Fuel connections are now safe for servicing.
5) Upon completion of servicing, install fuel pump relay to connec-
tor.

1. Fuel pump relay

2. Junction (Fuse) box

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 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-1

SECTION 6E1

ENGINE AND EMISSION CONTROL SYSTEM

(SEQUENTIAL MULTIPORT FUEL INJECTION FOR
G16/J20 ENGINE)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

6E1
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.

Whether the following systems (parts) are used in the particular vehicle or not depends on specifica-
tions. Be sure to bear this in mind when performing service work.
– EGR valve
– Heated oxygen sensor or CO adjusting resistor
– Three way catalytic converter

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 2

ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 2
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 4
On-Board Diagnostic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 4
Precautions in Diagnosing Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 4
B-1 Fuel Pump Circuit Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 5
Inspection of PCM (ECM) and Its Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 6
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 9
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 9
Fuel Injector (Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1- 9
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-11
Main Relay (Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-11
Fuel Pump Relay (Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E1-12

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 6E1-2 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE)

GENERAL DESCRIPTION
ELECTRONIC CONTROL SYSTEM
The electronic control system consists of 1) various
Idle air control system
sensors which detect the state of engine and driving
Fuel pump control system
conditions, 2) ECM (PCM) which controls various de-
Evaporative emission control system
vices according to the signals from the sensors and
Ignition control system
3) various controlled devices.
EGR system (if equipped)
Functionally, it is divided into the following sub sys- Also, with 4 A/T model, PCM controls A/T.
tems:

Fuel injection control system

Heated oxygen sensor heater control system (if
equipped)

G16 ENGINE

INFORMATION SENSORS CONTROLLED DEVICES OTHERS

1. MAF sensor a : Fuel pump relay A : PCM / ECM
2. VSS b : Injectors B : EVAP canister
3. Heated oxygen sensor (if equipped) c : EGR valve (if equipped) C : Data link connector
4. Power steering pressure switch d : Idle air control valve D : Combination meter
(if equipped) e : Ignition coil assemblies
5. ECT sensor g : Malfunction indicator lamp
6. Battery : (“CHECK ENGINE” light)
7. TP sensor h : Main relay
8. Transmission range switch (A / T only) i : EVAP canister purge valve
9. Camshaft position sensor (CMP sensor) j : A / C condenser fan motor relay
10. IAT sensor : (if equipped)
11. Ignition timing adjusting resistor
12. CO adjusting resistor (if equipped)
13. ABS control module (if equipped)
14. A / C amplifier (if equipped) NOTE:
15. Monitor connector Above figure shows left-hand steering vehicle. For right-hand steering vehicle,
parts with (*) are installed at the other side.

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 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-3

J20 ENGINE

INFORMATION SENSORS CONTROLLED DEVICES OTHERS

1. IAT sensor a : Idle air control valve A : ECM (PCM)
2. MAF sensor b : A / C condenser fan motor relay B : EVAP canister
3. Power steering pressure switch : (if equipped) C : Data link connector
(if equipped) c : EVAP canister purge valve D : Combination meter
4. Heated oxygen sensor (if equipped) d : Ignition coil assemblies
5. Monitor connector e : Main relay
6. ABS control module (if equipped) f : Fuel pump relay
7. Camshaft position sensor (CMP sensor) g : Malfunction indicator lamp
8. ECT sensor : (“CHECK ENGINE” light)
9. TP sensor h : Injectors
10. Battery i : EGR valve (if equipped)
11. CO adjusting resistor (if equipped)

NOTE:
Above figure shows left-hand steering vehicle. For right-hand steering vehicle,
parts with (*) are installed at the other side.

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 6E1-4 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE)

DIAGNOSIS
The engine and emission control system in this vehicle are con-
trolled by ECM/PCM. ECM/PCM has an On-Board Diagnostic sys-
tem which detects a malfunction in this system.
When diagnosing troubles, be sure to have full understanding of the
outline of “On-Board Diagnostic System” and each item in “Precau-
tion in Diagnosing Trouble” and execute diagnosis according to
“Engine Diagnostic Flow Table” in Section 6.

ON-BOARD DIAGNOSTIC SYSTEM

ECM/PCM performs on-board diagnosis (self-diagnosis) on the
system and operates “CHECK ENGINE” lamp (malfunction indica-
tor lamp) as follows.

Malfunction indicator lamp (“CHECK ENGINE” light) lights when
the ignition switch is turned ON (but the engine at stop) regardless
of the condition of Engine and emission control system. This is
only to check the malfunction indicator lamp (“CHECK ENGINE”
light) bulb and its circuit.

If the areas monitored by ECM/PCM is free from any trouble after
the engine start (while engine is running), malfunction indicator
lamp (“CHECK ENGINE” light) turns OFF.

When ECM/PCM detects a trouble which has occurred in the
areas, it makes malfunction indicator lamp (“CHECK ENGINE”
light) turn ON while the engine is running to warn the driver of such
occurrence of trouble and at the same time it stores the exact
trouble area in ECM/PCM back-up memory.

PRECAUTIONS IN DIAGNOSING TROUBLES

Before identifying diagnostic trouble code, don’t disconnect cou-
plers from ECM/PCM, battery cable from battery, ECM/PCM
ground wire harness from engine. Such disconnection will erase
memorized trouble in ECM/PCM memory.

Be sure to read “Precautions for Electrical Circuit Service” in Sec-
tion 0A before inspection and observe what is written there.

ECM/PCM replacement
When substituting a known-good ECM/PCM, check for following
conditions. Neglecting this check may cause damage to known-
good ECM/PCM.
– Resistance value of all relays, actuators is as specified re-
spectively.
– TP sensor and fuel tank pressure sensor (if equipped) are in
good condition and none of power circuits of these sensors is
shorted to ground.

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 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-5

B-1 FUEL PUMP CIRCUIT CHECK

5 1. Main fuse box

2. “IG” fuse
3. “FI” fuse
4. Ignition switch
5. “IG” circuit fuse
4 6. Main relay
7. Fuel pump relay
8. Fuel pump
9. ECM (PCM)

A2 (B6)

A14 (B17)

A15 (B26)

M / T Vehicle : ECM

A / T Vehicle : (PCM)

STEP ACTION YES NO

1 Is fuel pump heard to operate 3 Fuel pump and its circuit are in Go to Step 2.
seconds after ignition switch ON? good condition.
2 1) With ignition switch OFF, remove Go to Step 3. “P/B” or “B” wire open,
fuel pump relay from connector. poor fuel pump relay-to-
2) Using service wire, connect coupler connection or
two terminals of relay connector as faulty fuel pump.
shown in figure.
Is fuel pump heard to operate with
ignition switch ON?
3 1) Check fuel pump relay, referring Poor fuel pump relay-to-coupler Faulty fuel pump
to p.6E1-12 in this manual. connection, “W/G” wire open or relay.
Is it in good condition? poor A13 (A23) connection.
If wire and connection are OK,
substitute a known-good
ECM (PCM) and recheck.

Fig. for Step 2

Left hand steering vehicle Right hand steering vehicle

1. Service wire

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 6E1-6 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE)

INSPECTION OF PCM (ECM) AND ITS CIRCUITS

PCM (ECM) and its circuits can be checked at PCM (ECM) wiring
couplers by measuring voltage and resistance.

CAUTION:
PCM/ECM cannot be checked by itself. It is strictly prohib-
ited to connect voltmeter or ohmmeter to PCM (ECM) with
couplers disconnected from it.

M / T Vehicle

A / T Vehicle 2

1. PCM (ECM)
2. PCM (ECM) connector
(Viewed from harness side)

Voltage Check
Refer to the same item of the Service Manual mentioned in Fore-
word of this manual.

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 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-7

Resistance Check
1) Disconnect couplers from ECM/PCM with ignition switch OFF.

CAUTION:
Never touch terminals of ECM/PCM itself or connect
voltmeter or ohmmeter.

2) Check resistance between each pair of terminals of discon-

nected couplers as listed in following table.

CAUTION:

Be sure to connect ohmmeter probe from wire harness
side of coupler.

Be sure to turn OFF ignition switch for this check.

Resistance in table represents that when parts temper-
ature is 20C (68F).

1. ECM / PCM coupler disconnected

2. Ohmmeter

M/T VEHICLE
TERMINALS CIRCUIT STANDARD RESISTANCE CONDITION
A3 – A1 Main relay 79 – 95

A13 – B15 Fuel pump relay 79 – 95

Battery disconnected and
A26 – B15 A / C fan motor relay (if equipped) 75 – 110

ignition switch ON
D1 – B8 Fuel injector No.2
13 – 16

D2 – B8 Fuel injector No.1
D3 – B8 IAC valve (stepper motor coil 2)
35 – 43

D4 – B8 IAC valve (stepper motor coil 1)
EGR valve (stepper motor coil 2,
D7 – B8
if equipped)
20 – 24

EGR valve (stepper motor coil 1,
D8 – B8
if equipped)
D9 – B15 Heater of HO2S (if equipped) 11.7 – 14.3

D12 – B8 Fuel injector No.4
13 – 16

D13 – B8 Fuel injector No.3
D14 – B8 IAC valve (stepper motor coil 4)
35 – 43

D15 – B8 IAC valve (stepper motor coil 3)
EGR valve (stepper motor coil 4,
D18 – B8
if equipped)
20 – 24

EGR valve (stepper motor coil 3,
D19 – B8
if equipped)
D20 – B8 EVAP canister purge valve 28 – 35

A2 – Body ground Ground Continuity
A14 – Body ground Ground Continuity
A15 – Body ground Ground Continuity

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 6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE)

A/T VEHICLE
TERMINALS CIRCUIT STANDARD RESISTANCE CONDITION
A9 – A2 Main relay 79 – 95

Battery disconnected and
A22 – B20 A / C fan motor relay (if equipped) 75 – 110

ignition switch ON
A23 – B20 Fuel pump relay 79 – 95

B6 – Body ground Ground Continuity
B17 – Body ground Ground Continuity
B26 – Body ground Ground Continuity
C1 – Body ground Shift solenoid B
C2 – Body ground Shift solenoid A 11 – 15

C8 – Body ground TCC solenoid
D1 – B4 Fuel injector No.2
13 – 16

D2 – B4 Fuel injector No.1
D3 – B4 IAC valve (stepper motor coil 1) 35 – 43

D4 – B20 Heater of HO2S (if equipped) 11.7 – 14.3

D8 – B4 Fuel injector No.4
13 – 16

D9 – B4 Fuel injector No.3
D10 – B4 IAC valve (stepper motor coil 4)
D11 – B4 IAC valve (stepper motor coil 3) 35 – 43

D12 – B4 IAC valve (stepper motor coil 2)
EGR valve (stepper motor coil 4,
D13 – B4
if equipped)
EGR valve (stepper motor coil 3,
D14 – B4
if equipped)
20 – 24

EGR valve (stepper motor coil 2,
D15 – B4
if equipped)
EGR valve (stepper motor coil 1,
D16 – B4
if equipped)
D17 – B4 EVAP canister purge valve 28 – 35

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 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-9

ON-VEHICLE SERVICE
FUEL DELIVERY SYSTEM
FUEL INJECTOR
Inspection

WARNING:
As fuel is injected in this inspection, perform in a well venti-
lated area and away from open flames.
Use special care to prevent sparking when connecting and
disconnecting test lead to and from battery.

1) Install injector and fuel pressure regulator to special tool (injec-

tor checking tool).

Special Tool
(A): 09912-58421

2) Connect special tools (hoses and attachment) to hose and pipe

of vehicle.

Special Tool
(B): 09912-58431

3) Connect special tool (test lead) to injector.

Special Tool
(D): 09930-88530

1. Fuel feed pipe and hose

2. Fuel injector
3. Fuel pressure regulator
4. Fuel return pipe

4) Install suitable vinyl tube onto injector nozzle to prevent fuel from
Left hand Right hand
steering vehicle steering vehicle splashing out when injecting.
5) Put graduated cylinder under injector as shown.
6) Remove fuel pump relay.
7) To operate fuel pump and apply fuel pressure to injector, using
wire harness as thick as the one used for fuel pump circuit, con-
nect two terminals of relay connector as shown in figure.

CAUTION:
Check to make sure that connection is made between
1. Fuel pump relay
connector correct terminals. Wrong connection can cause damage
2. Service wire to PCM (ECM), wire harness, etc.
3. Junction (Fuse) box

Turn ignition switch ON.

8) Apply battery voltage to injector for 15 seconds and measure in-
jected fuel volume with graduated cylinder.
Test each injector two or three times.
If not within specification, replace injector.
Injected fuel volume:
42 – 52 cc/15 sec. (1.42/1.48 – 1.75/1.83 US/lmp. oz/15 sec.)
for G16 engine.
1. Injector 3. Keep as far apart 55 – 62 cc/15 sec. (1.94/2.09 – 2.18/2.36 US/lmp. oz/15 sec.)
2. Battery as possible
for J20 engine.

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 6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE)

1. Injector
9) Check fuel leakage from injector nozzle. Do not operate injector
2. Vinyl tube for this check (but fuel pump should be at work).
3. Less than one fuel
drop / min If fuel leaks more than the following specifications, replace.
4. Graduated cylinder
Fuel leakage: Less than 1 drop/min.

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 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-11

Left-hand steering vehicle ELECTRONIC CONTROL SYSTEM

MAIN RELAY
Inspection
1) Disconnect negative cable at battery.
2) Remove main relay from connector.

1. Main relay
2. Junction (Fuse) box
Right-hand steering vehicle

3) Check resistance between each two terminals as in table below.

TERMINALS RESISTANCE
Between A and B
(Infinity)
Between C and D 79 – 95
at 20_C, 68_F

If check results are as specified, proceed to next operation

check. If not, replace.

4) Check that there is continuity between terminals “A” and “B”

when battery is connected to terminals “C” and “D”.
If malfunction is found, replace.

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 6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE)

Left-hand steering vehicle FUEL PUMP RELAY

Inspection
1) Disconnect negative cable at battery.
2) Remove fuel pump relay from connector.
3) Structure of fuel pump relay is the same as that of main relay.
Check its resistance and operation using the same procedure as
that for main relay.
If malfunction is found, replace.

1. Fuel pump relay

2. Junction (Fuse) box
Right-hand steering vehicle

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 CHARGING SYSTEM 6H-1

SECTION 6H

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

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

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.

As regards items for 70A type generator which are not found in this section of this manual, refer to each
item applicable to 60A type generator described in the same section of the Service Manual mentioned

6H
in FOREWORD of this manual.

CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H- 2
GENERATOR [70 A type] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H- 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H- 3
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H- 3
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H- 3

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 6H-2 CHARGING SYSTEM

GENERAL DESCRIPTION
GENERATOR [70 A type]

1. Pulley 6. Field coil B : Generator output (Battery terminal)

2. Pulley nut 7. Regulator E : Ground
3. Rotor fan 8. Brush IG : Ignition terminal
4. Stator coil 9. Front housing L : Lamp terminal
5. Stator core 10. Rear housing

1. Generator with regulator ass’y 5. Field coil (rotor coil)

2. I.C. regulator 6. Charge indicator light
3. Stator coil 7. Main switch
4. Diode 8. Battery

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 CHARGING SYSTEM 6H-3

SPECIFICATIONS
BATTERY
NOTE:
The battery used in each vehicle is one of the following three types, depending on specification.

Group GP26R GP85R

Cold Cranking Ampere (A) 390 550
Load Test (A) 190 220
Rated Capacity (AH/5HR, 12 Volts) 36 48

GENERATOR
NOTE:
The generator used in each vehicle is one of the following two types, depending on specification.

Type 60 A type 70 A type

Rated voltage 12 V
Nominal output 60 A 70 A
Permissible max. speed 18000 r/min.
No-load speed 1300 r/min (rpm)
Setting voltage 14.4 to 15.0 V
Permissible ambient
–30 to 90_C (–22 to 194_F)
temperature
Polarity Negative ground
Rotation Clockwise viewed from pulley side

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 AUTOMATIC TRANSMISSION (4 A / T) 7B1-1

SECTION 7B1

AUTOMATIC TRANSMISSION
(4 A/T)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

7B1
CONTENTS

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1- 2

Manual Selector Assembly (For LH Vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1- 2
Key Interlock Cable (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1- 3

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 7B1-2 AUTOMATIC TRANSMISSION (4 A / T)

ON-VEHICLE SERVICE
MANUAL SELECTOR ASSEMBLY (FOR LH VEHICLE)

1. Manual selector assembly

(Select lever assembly)
2. Manual lever assembly
3. Select cable bracket
4. Select indicator
5. Slide cover
6. Select lever knob
7. Spring
8. Knob button
9. Shift lock solenoid rod
10. Shift lock solenoid
11. Cover
12. Illumination lamp
13. Interlock cam

Tightening Torque
(Manual selector assembly bolts)
(a): 18 N.m (1.8 kg-m, 13.5 lb-ft)

REMOVAL
1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connector for illumination lamp, shift lock solenoid
(if equipped) and overdrive OFF switch.
4) Disconnect interlock cable from interlock cam of selector as-
sembly (if equipped).
5) Remove selector assembly mounting bolts.
6) Disconnect select cable from lever of selector assembly.

INSTALLATION

NOTE:
If equipped with brake interlock system, new selector assem-
bly is supplied with held interlock cam at interlock cable con-
necting position with pin. Remove this pin after connecting in-
terlock cable to interlock cam and tightening cable nut.

1. Interlock cam pin

(only for new selector assembly)

Reverse removal procedure to install noting the followings.

Connect interlock cable end to cam referring to “Interlock Cable
Installation” section (if equipped).

Upon completion of installation, confirm that brake (key) interlock
system operates properly (if equipped).

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 AUTOMATIC TRANSMISSION (4 A / T) 7B1-3

KEY INTERLOCK CABLE (IF EQUIPPED)

NOTE:
Don’t bend interlock cable excessively when removing and
installing it, or system will not operate correctly.

Removal
1) Disconnect negative (–) cable from battery.
2) If equipped with air bag system, disable air bag system.
Refer to “Disabling Air bag System” in Section 10B.
3) Remove steering column hole cover.
4) Tilt steering column if steering column is adjustable.
If no adjustable, loosen steering column bolts.
5) Remove steering column cover.

Ignition switch side

6) Remove interlock cable clamp screw located at ignition switch
ass’y.
7) Remove disconnect interlock cable inner end.
(Ignition switch side.)

1. Ignition switch ass’y

2. Clamp screw
3. Interlock cable

Select lever side

8) With console box removed, take out interlock cable by loosening
lock nuts.
9) Detach cable end from interlock cam while pressing claws of in-
terlock cam boss. At this time, be careful not to cause damage
to its claws.

1. Inner end of interlock cable 4. Cam boss

2. Interlock cam 5. Claw
3. Stud bolt

Installation
1) Shift select lever to “N” range and turn ignition key to “ACC” posi-
tion.
2) Connect inner end of interlock cable to key interlock lever (Igni-
tion switch side).
3) Install outer end bracket of interlock cable to ignition switch as-
sembly, and tighten screw to specified torque.
1. Ignition switch ass’y
2. Clamp screw Tightening Torque
3. Outer end
(a): 2.2 N.m (0.22 kg-m, 1.5 lb-ft)

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 7B1-4 AUTOMATIC TRANSMISSION (4 A / T)

4) Pass and connect interlock cable as shown at the left figure.

1. Interlock cable
2. Steering column
3. Steering column
holder

5) Fix interlock cam by inserting pin with about 4 mm (0.15 in.) dia.
into holes of cam and lever plate.
6) Install cable end to interlock cam and stud bolt and after making
sure that cable outer is pushed in arrow direction B by leaf
spring, tighten mounting nut to specified torque. Remove pin.

Tightening Torque
(a): 13 N.m (1.3 kg-m, 9.5 lb-ft)

7) Turn ignition key to “ACC” position and shift select lever to “N”
range, and check for followings.
a. When select lever is shifted at “P” range with knob button
depressed, ignition key can not be turned from “ACC” to
“LOCK” position.
b. When knob button is released, ignition key can be turned to
“LOCK” position.
c. When ignition key is at “LOCK” position, select lever can not
be shifted from “P” to any other range.
8) Install console box.
9) Install steering column cover and steering column hole cover.
10) Adjust steering column or tighten steering column bolts.
11) If equipped with air bag system, enable air bag system.
Refer to “Enabling Air bag System” in Section 10B.

1. Interlock cam
2. Lever plate
3. Interlock cable
4. Pin with 4 mm (0.15 in.) dia.

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 LIGHTING SYSTEM 8B-1

SECTION 8B

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

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B- 2

Hazard Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B- 2

8B

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 8B-2 LIGHTING SYSTEM

ON-VEHICLE SERVICE
HAZARD RELAY
INSPECTION
Connect battery and tester as shown.
Unless a continued click sound is heard, replace relay.

Type A

23
Type B

1. Hazard relay
2. Junction box
3. Fuse box

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 INSTRUMENTATION / DRIVER INFORMATION 8C-1

SECTION 8C

INSTRUMENTATION/DRIVER INFORMATION
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C- 2

Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C- 2

8C

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 8C-2 INSTRUMENTATION / DRIVER INFORMATION

GENERAL DESCRIPTION
COMBINATION METER

NOTE:
Terminal arrangement of coupler viewed from harness side.

Coupler A Coupler B Coupler C

Coupler A Coupler B Coupler C

1. Blank 1. To door switch (driver side) B / Bl 1. To ground B
2. Blank 2. To shift switch (A / T vehicle only) L G / Bl 2. To ECM (PCM for A / T vehicle) Br
3. To ignition switch B/W 3. To shift switch (A / T vehicle only) 2 G/O 3. To ignition switch V/R
4. Blank 4. To shift switch (A / T vehicle only) D Y/G 4. To brake fluid level switch R/B
5. To ABS control module Bl / O 5. To shift switch (A / T vehicle only) N O / Bl 5. To parking brake switch V
6. To PCM (A / T vehicle only) Gr / Bl 6. To shift switch (A / T vehicle only) P O/G 6. To seat belt switch (if equipped) Gr / R
7. Blank 7. To shift switch (A / T vehicle only) R R 7. To generator W/R
8. To VSS Bl / Y 8. To ground B 8. To oil pressure switch Y/B
9. To combination switch G/R 9. To PCM (A / T vehicle only) W/B 9. To combination switch R/Y
10. To SDM Y/G 10. To ECT sensor Y/W 10. Blank
11. To main fuse W / Bl 11. To fuel level gauge Bl / W
12. To fuse box W 12. To ground B/Y
13. To combination switch R 13. To combination switch G/Y
14. Blank
15. To ECM (PCM for A / T vehicle) V/Y
16. To 4WD controller O/B

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 WINDOWS, MIRRORS, SECURITY AND LOCKS 8D-1

SECTION 8D

WINDOWS, MIRRORS, SECURITY AND LOCKS

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

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D- 2

Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D- 2

8D

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 8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS

Type A ON-VEHICLE SERVICE

WINDSHIELD WIPER
INSPECTION
Wiper Motor
1) As illustrated, use a 12 V battery to connect its (+) terminal to ter-
Type B minal “A”, and its (–) terminal to Black lead wire.
If motor rotates at a low revolution speed of 45 to 55 rpm, it is
proper. For high speed check, connect battery (+) terminal to ter-
minal “B”, and its (–) terminal to Black lead wire. If motor rotates
at a high revolution speed of 67 to 83 rpm, it is proper.

Type C

2) Testing automatic stop action.

Type A
a) Connect 12 V battery (+) terminal to terminal “A” of wiper mo-
tor and (–) terminal to Black lead wire and let the motor turn.
b) Disconnect terminal “A” from battery, and let the motor stop.
c) Connect terminal “A” and “D” with a jumper wire, and connect
terminal “C” to battery (+) terminal. Observe the motor turns
once again then stops at a given position.
d) Repeat a) thru c) several times and inspect if the motor stops
at the given position every time.

Type B

Type C

1. Battery
2. Wiper motor
3.
-Red lead
4.  -Black lead
5. Jumper

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 BODY SERVICE 9-1

SECTION 9

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

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

When body servicing, if shock may be applied to air bag system component parts, remove those parts
beforehand. (Refer to Section 10B.)

NOTE:

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

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

CONTENTS

BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 2
Front Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 2
Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 3

9
Body Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 4
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 7
Rear Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 7
PAINT AND COATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 8
Metal Replacement Parts Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 8
CONVERTIBLE TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Canvas Top And Topbow Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
EXTERIOR AND INTERIOR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Roof Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

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 9-2 BODY SERVICE

BODY STRUCTURE
FRONT FENDER

1. Front fender
2. Front fender lining
3. Fender attaching bolts
4. Fender lining attaching screws

REMOVAL
1) Remove front bumper.
2) Remove fender splush guard (H25 engine).
3) Remove front fender lining.
4) Remove front fender.

INSTALLATION
1) Remove pad from side body and (or) fender, using care not to
damage painted surface.

1. Side body
2. Fender
3. Pad

2) Attach new pad cutting appropriately size temporarily and adjust

height with a knife so that fender becomes flush with side body.
3) Reverse removal procedure for installation.

NOTE:
If paint on fender bolt is peeled off, be sure to apply paint
again.
1. Side body
2. Pad
3. Knife

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 BODY SERVICE 9-3

REAR BUMPER

1. Rear bumper
2. Rear bumper member
3. Rear bumper garnish (if equipped)

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 9-4 BODY SERVICE

BODY DIMENSIONS
Canvas top model

a. Garnish installation clip hole

b (b’). Front end of front windshield lower installation section
c (c’). Front end of front windshield upper installation section
d. Hole in F door lower hinge at rear
e. Trim installation clip hole
f (f’). Scuff installation hole (at rearmost end)
g (g’). Trim installation hole
h (h’).
11 jig hole
i. Installation hole for F seat front inside
j. Installation hole for F seat rear inside
k (k’). F seat belt installation hole
l (l’). Innermost end of side body installation section

Hole to hole distance

a – c : 981 mm (38.62 in.) g – g’ : 1145 mm (45.08 in.)
b – b’ : 1390 mm (54.72 in.) g–h : 1017 mm (40.04 in.)
b – c’ : 1404 mm (55.28 in.) g–j : 1078 mm (42.44 in.)
c – c’ : 1008 mm (39.69 in.) h – h’ : 1338 mm (52.68 in.)
e – e’ : 1110 mm (43.70 in.) h–j : 1459 mm (57.44 in.)
e – i : 1036 mm (40.79 in.) j–k : 548 mm (21.57 in.)
f – i : 688 mm (27.09 in.) l – l’ : 956 mm (37.64 in.)

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 BODY SERVICE 9-5

a. Hole in door upper hinge at rear

b. Hole in door lower hinge at rear
c. Trim installation clip hole
d.
7 jig hole
e. Scuff installation hole (rearmost end)
f. Door striker lower section installation hole
g. F seat belt installation hole

Hole to hole distance

a – d : 1154 mm (45.43 in.)
a – f : 1150 mm (45.28 in.)
b – f : 1165 mm (45.87 in.)
c – e : 1142 mm (44.96 in.)
c – g : 1246 mm (49.06 in.)
d – e : 1146 mm (45.12 in.)

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 9-6 BODY SERVICE

a (a’). Trim installation clip hole

b. Installation hole in uppermost part of upper hinge
c. Installation hole in outside part of lower hinge
d. Installation hole in uppermost part of rear gate striker
e (e’). Installation hole in outer upper section of R-COMB R (L) lamp
f (f’). Innermost end of rear floor tail member installation section
g (g’). Garnish installation clip hole

Hole to hole distance

a – a’ : 1112 mm (43.78 in.)
a – f’ : 1134 mm (44.65 in.)
a – g’ : 796 mm (31.34 in.)
a’ – f : 1156 mm (45.51 in.)
a’ – g : 824 mm (32.44 in.)
b – d : 1229 mm (48.39 in.)
c – d : 1324 mm (52.13 in.)
e – e’ : 1544 mm (60.79 in.)
f – f’ : 1029 mm (40.51 in.)

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 BODY SERVICE 9-7

SEAT
REAR SEAT

1. Seat cushion
2. Seat back
3. Seat auto lock release handle
4. Seat hinge male
5. Hinge male cover

REMOVAL
1) Remove four mounting bolt to remove seat cushion.
2) Remove four mounting bolts to remove seat back.
3) Disassemble and repair seat as necessary.

INSTALLATION
Reverse removal procedure to install rear seat.
Torque to specifications, as shown.

Tightening Torque
(a): 35 N.m (3.5 kg-m, 25.5 lb-ft)

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 9-8 BODY SERVICE

PAINT AND COATING

METAL REPLACEMENT PARTS FINISHING
SEALANT APPLICATION AREA
Canvas top model

1. Side body inner panel 5. Front floor panel “A”: Apply sealant
2. Rear wheel housing panel 6. Center floor member “B”: Brush treatment
3. Rear floor panel 7. Side sill inner panel
4. Center floor panel

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 BODY SERVICE 9-9

1. Cowl top panel “A”: Apply sealant

2. Dash panel “B”: Brush treatment
3. Cowl front panel
4. Front floor panel
5. Front pillar inner lower panel

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 9-10 BODY SERVICE

1. Side body inner panel “A”: Apply sealant

2. Side body outer panel “B”: Brush treatment
3. Front pillar inner panel “C”: Wipe
4. Front pillar upper reinforcement
5. Rear wheel housing panel
6. Fuel inlet box
7. Center pillar reinforcement
8. Center pillar joint outer panel
9. Center pillar joint inner panel
10. Tail upper member
11. Back pillar outer panel

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 BODY SERVICE 9-11

Be free from protrude

of sealant outside from
this line

Sealant width “W”: more than 5 mm

“A”: Apply sealant

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 9-12 BODY SERVICE

UNDERCOATING/ANTI–CORROSION COMPOUND APPLICATION AREA

Canvas top model

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 BODY SERVICE 9-13

“a”

“a”: 30 mm (1.18 in.) 1. Side body outer

2. Side sill inner
3. Main floor
4. Front fender
“A”: Apply undercoating (PVC, 400 mm or more) 5. Front wheel housing
“B”: Additional applying of under coating 6. Frame
“B”: (for 5 door vehicle without splush guard) 7. Dash panel
“C”: Apply PVC chip resistant material (200 mm or more) 8. Center floor
9. Rear floor

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 9-14 BODY SERVICE

“a”: 240 mm (9.45 in.)

“b”: 20 mm (0.79 in.)
“c”: 40 mm (1.57 in.)
“d”: 134 mm (5.28 in.)
“e”: 177 mm (6.97 in.)

“A”: Black paint

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 BODY SERVICE 9-15

CONVERTIBLE TOP
CANVAS TOP AND TOPBOW FRAMES
Removal
1) Open canvas to referring to Owner’s Manual.
2) Remove fording top and rear canvas top.
3) Remove topbow bracket cover.

1. Topbow center flame

2. Bracket cover

4) Remove topbow center frame.

5) Remove topbow front frame.

1. Topbow front frame

Installation
Install in reverse order of removal procedure.

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 9-16 BODY SERVICE

EXTERIOR AND INTERIOR TRIM

FLOOR CARPET

1. Front floor carpet

2. Luggage floor carpet
3. Dash panel insulation

FRONT FLOOR CARPET

REMOVAL
1) Remove front seats and rear seat cushions.
2) Remove seat belt lower anchor bolt.
3) Remove dash side trims, front side sill scuffs (5 door and 3 door
model), center pillar inner lower rims (5 door and 3 door model),
rear side sill scuffs (5 door and 3 door model), side sill scuffs
(Canvas top model) and rear quarter lower trim.
4) Remove parking brake lever cover, console box and console
box front extension.
5) Remove front floor carpet.

INSTALLATION
Reverse removal sequence to install front floor carpet, noting fol-
lowing point.

When tightening seat belt anchor bolt, refer to Section 10A
“FRONT SEAT BELT WITHOUT PRITENSIONER” for tightening
1. Dash side trim 4. Rear side sill scuff
2. Front side sill scuffs 5. Fastener
torque.
3. Center pillar inner 6 Side sill scuff
lower trim 7. Rear quarter lower trim

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 BODY SERVICE 9-17

ROOF TRIM
REMOVAL
1) Remove canvas top
2) Remove rear topbow.
3) Remove side body garnishes.
4) Remove luggage mat end garnish.
5) Remove assistant grips.
6) Remove sunshade assemblies.
7) Remove sunshade hooks.
8) Remove front topbow locks.
9) Remove canvas top snaps.
10) Remove front seat belts.
11) Remove front pillar trims.
12) Remove rear side inner lower trims.
13) Remove rear side inner upper trims.
14) Disconnect room light connector and remove room light har-
ness clamp.
15) Remove roof trim.

CAUTION:
Be very careful not to separate roof trim consists of 4
components when removing. If disassemble it, it could
not be assembled to original unit.

1. Canvas top
2. Rear topbow
3. Side body garnish
4. Luggage mat end garnish
5. Assistant grip
6. Sunshade assembly
7. Sunshade hook
8. Front topbow lock
9. Canvas top snap
10. Front seat belt
11. Front pillar trim
12. Rear side inner lower trim
13. Rear side inner upper trim
14. Room light connector
15. Room light harness clamp
16. Roof trim
17. Left-front seat belt

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 9-18 BODY SERVICE

INSTALLATION
1) Set room light and clip to roof trim.
2) Set room light harness to roof trim with marking tape.

1. Roof trim 4. Clip

2. Room light 5. Screw
3. Room light lens 6. Room light harness
7. Marking tape

3) Reverse removal sequence to install roof trim.

Tightening Torque
(a): 35 N.m (3.5 kg-m, 25.3 lb-ft)

1. Seat belt

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 SEAT BELT 10A-1

SECTION 10A

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

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al Description” in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in air bag system section before performing 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).

The procedures in this section must be followed in the order listed to disable the air bag system tem-
porarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could
result in possible activation of the air bag system, personal injury or otherwise unneeded air bag sys-
tem repairs.

CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called
out. The correct torque value must be used when installing fasteners that require it. If the above proce-
dures are not followed, parts or system damage could result.

NOTE:

To check whether the vehicle is equipped with a seat belt pretensioner or not, refer to the Owner’s Manu-
al.

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

10A
mentioned in FOREWORD of this manual.

CONTENTS

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A- 2

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A- 2
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A- 2
Front Seat Belt with Pretensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A- 3

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 10A-2 SEAT BELT

ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
HANDLING AND STORAGE
NOTE:
Whether the pretensioner has activated or not can be judged
by the sealing tape attached on retractor assembly. If it has
been torn by generated gas, the pretensioner has activated.

LIVE (INACTIVATED) SEAT BELT PRETENSIONER

WARNING:
Never attempt to measure the resistance of the pretension-
er. It is very dangerous as the electric current from the tester
may activate the pretensioner.

Special care is necessary when handling and storing a live (inacti-

vated) pretensioner.
Also, when the seat belt pretensioners activate, gas is generated
and the seat belt is retracted into the retractor quickly. Note, there-
fore, that if they activate accidentally, the seat belt pretensioners
and other object(s) around them may be thrown through the air.

Never attempt disassembly of the seat belt pretensioner (retrac-
tor assembly).

If any abnormality is found, be sure to replace it with new one as
an assembly.

When an abnormality is noted as existing in the live (inactivated)
seat belt pretensioner, be sure to activate it before discarding it.
(Refer to “Seat Belt Pretensioners Disposal” in SECTION 10B.)

When grease, cleaning agent, oil water, etc., got on the seat belt
pretensioner (retractor assembly), wipe it off immediately with a
dry cloth.

If seat belt pretensioner (retractor assembly) was dropped from
a height of 30 cm (1 ft) or more, it should be replaced.

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 SEAT BELT 10A-3

WARNING:
D For handling and storage of a live seat belt pretensioner,
select a place where the ambient temperature below
65_C (150_F), without high humidity and away from elec-
tric noise.
D Never carry the seat belt pretensioner by the wires or
connector on the underside of the pretensioner.
D When placing a live seat belt pretensioner on the work-
bench or some place like that, be sure not to lay it with
NG NG its exhaust hole provided side facing down. It is also pro-
hibited to put something on its face with an exhaust hole
or to put a seat belt pretensioner on top of another.
Otherwise, personal injury may result.

1. Exhaust hole

FRONT SEAT BELT WITH PRETENSIONER

INSPECTION
When checking seat belt with pretensioner, use following check
items in addition to those specified for seat belt without pretension-
er described in the same section of the Service Manual mentioned
in FOREWORD of this manual.

WARNING:
Never measure resistance of pretensioner or disassemble
it. Otherwise, personal injury may result.

CAUTION:
If seat belt pretensioner (retractor assembly) was dropped
from a height of 30 cm (1 ft) or more, it should be replaced.

Check retractor assembly with seat belt pretensioner appearance

visually for following symptoms and if any one of them is applicable,
replace it with a new one as an assembly.
D Pretensioner has activated.
D There is a crack in seat belt pretensioner (retractor assembly).
D Wire harness or connector is damaged.
D Seat belt pretensioner (retractor assembly) is damaged or a
strong impact (e.g., dropping) was applied to it.

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 AIR BAG SYSTEM 10B-1

SECTION 10B

AIR BAG SYSTEM

WARNING:

Service on or around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle
Service” in this section before performing service on or around the air bag system components or
wiring. Failure to follow WARNINGS could result in unintended activation of the system or could ren-
der the system inoperative. Either of these two conditions may result in severe injury.

The procedures in this section must be followed in the order listed to disable the air bag system tem-
porarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could
result in possible activation of the air bag system, personal injury or otherwise unneeded air bag sys-
tem repairs.

CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called
out. The correct torque value must be used when installing fasteners that require it. If the above condi-
tions are not followed, parts or system damage could result.

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual men-
tioned in FOREWORD of this manual.

CONTENTS

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B- 2

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B- 2
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B- 2

10B

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 10B-2 AIR BAG SYSTEM

ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
HANDLING AND STORAGE
LIVE (INACTIVATED) SEAT BELT PRETENSIONERS
Special care is necessary when handling and storing a live (inacti-
vated) seat belt pretensioners.
Also, when the seat belt pretensioners activate, gas is generated
and the seat belt is retracted into the retractor quickly.
Note, therefore, that if they activate accidentally, the seat belt pre-
tensioners and other object(s) around them may be thrown through
the air.

2-1. Webbing
2-2. Retractor assembly
2-1. Seat belt pretensioner
2-2. Seat belt pretensioner harness

WARNING:
Never attempt to measure the resistance of the seat belt pre-
tensioners. It is very dangerous as the electric current from
the tester may activate pretensioner.

Never attempt to disassemble the seat belt pretensioners (retrac-

tor assembly).

If any abnormality is found, be sure to replace it with new one as
an assembly.

When an abnormality is noted as existing in the live (inactivated)
seat belt pretensioner, be sure to activate it before discarding it.

When grease, cleaning agent oil, water, etc., got on the seat belt
pretensioners (retractor assembly), wipe it off immediately with a
dry cloth.

If seat belt pretensioner was dropped from a height of 30 cm (1
ft) or more, it should be replaced with a new one as an assembly.

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 AIR BAG SYSTEM 10B-3

WARNING:

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

Never carry the seat belt pretensioner by the wires or con-
nector on the underside of the pretensioner.

When placing a live seat belt pretensioner on the work-
bench or some place like that, be sure not to lay it with its
NG NG exhaust hole provided side facing down. It is also prohib-
ited to put something on its face with an exhaust hole or
to put a seat belt pretensioner on top of another.
Otherwise, personal injury may result.

1. Exhaust hole

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 Prepared by

Overseas Service Department

1st Ed. Sept., 1998

Printed in Japan

Printing: Dec., 1998 124

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