99500_60G20_01E_V1_1.pdf

IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions

carefully. To emphasize special information, the words

WARNING , CAUTION and NOTE have special mean-

ings. Pay special attention to the messages high-

lighted by these signal words.

WARNING:

For vehicles equipped with Supplemental

Restraint (Air Bag) System:

Service on or around the air bag system

components must be performed only by

an authorized SUZUKI dealer. Please ob-

serve all WARNINGS, CAUTIONS and

“Service Precautions” under “On-Vehicle

Service” in SECTION 10B before perform-

ing service on or around the air bag sys-

tem components or wiring. Failure to

follow WARNINGS could result in uninten-

tional activation of the system or could

render the system inoperative. Either of

these two conditions may result in severe

injury.

WARNING:

Indicates a potential hazard that could result

in death or injury.

CAUTION:

Indicates a potential hazard that could result

in vehicle damage.

NOTE:

Indicates special information to make mainte-

nance easier or instructions clearer.

If the air bag system and another vehicle

system both need repair, SUZUKI recom-

mends that the air bag system be repaired

first, to help avoid unintentional activa-

tion of the air bag system.

Do not modify the steering wheel, instru-

ment panel or any other air bag system

component. Modifications can adversely

affect air bag system performance and

lead to injury.

If the vehicle will be exposed to tempera-

tures over 93

WARNING:

This service manual is intended for autho-

rized SUZUKI dealers and qualified service

mechanics only. Inexperienced mechanics

or mechanics without the proper tools and

equipment may not be able to properly per-

form the services described in this manual.

Improper repair may result in injury to the

mechanic and may render the vehicle un-

safe for the driver and passengers.

F) (for example, dur-

ing a paint baking process), remove the

air bag system components (air bag (infla-

tor) modules, SDM and seat belt preten-

sioner (if equipped)) beforehand to avoid

component damage or unintended activa-

tion of the system.

C (200

FOREWORD

This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service op-

erations, replacement of components (Service) and for disassembly and assembly of major components (Unit Re-

pair-Overhaul).

VOLUME 1 contains Chassis, Electrical and Body sections (all sections except engine).

VOLUME 2 contains Engine sections (Section 6 – 6K).

Applicable model: SY413/SY416/SY418 on and after the following VIN NO.

HATCHBACK

GA11S-200001

JSAEGA11S00200001

JSAEGA41S00200001

JSAEGA31S00200001

JSAEGB31S00200001

SEDAN

GC11S-200001

JS2GB31S

15200001

JSAEGC31S15200001

GC31S-200001

JS2GB41S

15200001

JSAEGC41S00200001

JS2GA11S

15200001

JSAEGC11S00200001

JSAEGD31S00200001

JS2GA31S

15200001

JSAEGC31S00200001

JS2GA41S

15200001

JSAEGC31S10200001

WAGON

GC31W-200001

JS2GB31W

15200001

JSAEGC31W10200001

GC41W-200001

JS2GB41W

15200001

JSAEGC31W15200001

JS2GA31W

15200001

JSAEGC11W00200001

JSAEGC41W00200001

JS2GA41W

15200001

JSAEGC31W00200001

JSAEGD31W00200001

The contents are classified into sections each of which is given a section number as indicated in the Table of Con-

tents on next page. And on the first page of each individual section is an index of that section.

This manual should be kept in a handy place for ready reference of the service work.

Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.

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

service materials (lubricant, sealants, etc.) as specified in each description.

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

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

dard specifications among others.

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

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

RELATED MANUAL

SY413/SY416/SY418 Wiring Diagram Manual

(99512-60G60-015)

OVERSEAS SERVICE DEPARTMENT

TABLE OF CONTENTS

SECTION

TABLE OF CONTENTS

SECTION

6-1

ENGINE

Engine (G13/G16 Engine without

WU-TWC)

Engine General Information and

Diagnosis

(G13/G16 Engine with WU-TWC)

Engine General Information and

Diagnosis

(J18 Engine with WU-TWC)

Engine Mechanical

(G13 and G16 Type Engine)

Engine Mechanical

(J18 Type Engine)

Engine Cooling

Engine Fuel

Electronic Fuel Injection System

(G13/G16 Engine without

WU-TWC)

Engine and Emission Control

System

(G13/G16 Engine with WU-TWC)

Electronic Fuel Injection System

(J18 Engine without WU-TWC)

Engine and Emission Control Sys-

tem (J18 Engine with WU-TWC)

Ignition System (G13/G16 Engine)

Ignition System (J18 Engine)

Cranking System

(0.8 kW Reduction Type)

Cranking System

(0.8 kW Conventional Type)

Cranking System

(0.9/1.2/1.4 kW Reduction Type)

Charging System

Exhaust System

GENERAL INFORMATION

General Information

Maintenance and Lubrication

6-2

6A1

HEATING AND VENTILATION

Heater and Ventilation

Air Conditioning (Optional)

6-1

6A3

6-2

STEERING, SUSPENSION,

WHEELS AND TIRES

Steering, Suspension,

Wheels and Tires

Front End Alignment

Manual Rack and Pinion

Power Steering (P/S) System

(Hydraulic Type)

Steering Wheel and Column

(Without Air Bag)

Air Bag Steering and Column

Front Suspension

Rear Suspension (2WD)

Rear Suspension (4WD)

Wheels and Tires

Suspension Control System

6A1

6E1

3B1

6A3

6E2

3C1

6E3

3B1

6E4

6E1

6F1

3C1

6E2

3E1

6F2

6G1

3E1

6E3

6G2

6E4

6G3

6F1

DRIVE SHAFT

Front Drive Shaft (DOJ Type)

Front Drive Shaft

(Tripod Joint Type)

Propeller Shafts

Rear Drive Shaft

6F2

6G1

6G2

6G3

7A1

BRAKE SYSTEM

Brakes

Antilock Brake System (ABS)

7A2

TRANSMISSION AND CLUTCH

Manual Transmission

(G13 and G16 Engine Models)

Manual Transmission

(J18 Engine Model)

Manual Transmission (4WD)

Automatic Transmission (3 A/T)

Automatic Transmission (4 A/T)

Clutch (Cable Type)

Clutch (Hydraulic Type)

Rear Differential

7B1

7A1

7A2

7C1

7B1

7C1

BODY ELECTRICAL SYSTEM

WIRING DIAGRAM

IMMOBILIZER CONTROL SYSTEM

BODY SERVICE

AIR BAG SYSTEM

NOTE:

The screen toned Sections 6 – 6K are included in Volume 2 of 2 and Section 8A is in Wiring Diagram Manual.

GENERAL INFORMATION

0A-1

SECTION 0A

GENERAL INFORMATION

CONTENTS

HOW TO USE THIS MANUAL

. . . . . . . . . . . . . .

0A- 2

Identification Whether Vehicle Equipped

With WU-TWC or Not

. . . . . . . . . . . . . . . . . .

Engine Identification Number

0A-16

PRECAUTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . .

Precaution for Vehicle Equipped with a

Supplemental Restraint (Air Bag) System

0A- 3

. . . . . . . . . . . . .

Transmission Identification Number

0A-16

. . . . . . .

0A-16

0A- 3

General Precautions

. . . . . . . . . . . . . . . . . . . .

Precaution for Catalytic Converter

0A- 7

WARNING, CAUTION AND INFORMATION

LABELS

. . . . . . . . .

Precautions for Electrical Circuit Service

0A-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-17

. . .

0A-10

VEHICLE LIFTING POINTS

. . . . . . . . . . . . . . . .

0A-18

Precaution for Installing Mobile

Communication Equipment

ABBREVIATIONS AND SYMBOLS MAY BE

USED IN THIS MANUAL

. . . . . . . . . . . . . .

Precaution in Servicing Full Time 4WD

Vehicle

0A-13

. . . . . . . . . . . . . . . . . . .

0A-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intermittent and Poor Connection

0A-14

FASTENER INFORMATION

. . . . . . . . . . . . . . . .

0A-23

. . . . . . . . .

0A-15

Metric Fasteners

. . . . . . . . . . . . . . . . . . . . . . . .

Fastener Strength Identification

0A-23

IDENTIFICATION INFORMATION

. . . . . . . . . . .

0A-16

. . . . . . . . . . .

0A-23

Vehicle Identification Number

. . . . . . . . . . . . .

0A-16

Standard Tightening Torque

. . . . . . . . . . . . . .

0A-24

0A-2

GENGERAL INFORMATION

HOW TO USE THIS MANUAL

1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL

on the first page of this manual, whereby you can easily find the

section that offers the information you need. Also, there is a

TABLE OF CONTENTS on the first page of EACH SECTION,

where the main items in that section are listed.

2) Each section of this manual has its own pagination. It is indi-

cated at the top of each page along with the Section name.

3) The SPECIAL TOOL usage and TIGHTENING TORQUE

SPECIFICATION are given as shown in figure below.

6) Install oil pump. Refer to Item “Oil pump” for installation of

oil pump.

7) Install flywheel (M/T vehicle) or drive plate (A/T vehicle).

Using special tool, lock flywheel or drive plate, and tighten

flywheel or drive plate bolts to specification.

Special Tool

(A): 09924-17810

Tightening Torque

(c): 78 N·m (7.8 kg-m, 56.5 lb-ft)

1. Flywheel bolts or drive plate bolts for A/T vehicle

4) A number of abbreviations and symbols are used in the text.

For their full explanations, refer to “ABBREVIATIONS AND

SYMBOLS MAY BE USED IN THIS MANUAL” of this section.

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

manual.

6) DIAGNOSIS and CORRECTION are included in each section

as necessary.

7) At the end of each section, there are descriptions of SPECIAL

TOOLS, REQUIRED SERVICE MATERIALS and TIGHT-

ENING TORQUE SPECIFICATIONS that should be used for

the servicing work described in that section.

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