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Suzuki Canvas SQ416 Service Manual
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Suzuki Canvas SQ416 Service Manual

Suzuki sq416; suzuki sq420
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  • Page 2 D 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”...
  • Page 3 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.
  • Page 4 TABLE OF CONTENTS SECTION GENERAL INFORMATION General Information HEATING AND AIR CONDITIONING Air Conditioning STEERING, SUSPENSION, WHEELS AND TIRES Power Steering (P/S) System Air Bag Steering Wheel and Column Front Suspension Rear Suspension Wheel and Tires DRIVE SHAFT/PROP. SHAFT Front Drive Shaft/Shaft Bearing, Oil Seal BRAKES Brake Pipe/Hose /Master...

  • Page 5: General Information

    GENERAL INFORMATION 0A-1 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 .
  • Page 6 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.
  • Page 7 GENERAL INFORMATION 0A-3 SERVICING AND HANDLING ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG OPENING) AWAY WARNING: FROM BODY. 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.
  • Page 8 0A-4 GENERAL INFORMATION WARNING: 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.
  • Page 9 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.
  • Page 10 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.
  • Page 11 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 by the shape of the service (charge) valve. 2.
  • Page 12 AIR CONDITIONING (OPTIONAL) 1B-3 COMPONENT LOCATION IN ENGINE ROOM G16 LH steering vehicle 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.
  • Page 13 1B-4 AIR CONDITIONING (OPTIONAL) RECOVERY, EVACUATION AND G16 LH steering vehicle shown 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.
  • Page 14 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 –...
  • Page 15 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.
  • Page 16 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.
  • Page 17 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.
  • Page 18 AIR CONDITIONING (OPTIONAL) 1B-9 4) Remove filter cover. LH steering vehicle shown 1. Filter cover 5) Pull out filter element. Pull out upper filter first then the lower one. LH steering vehicle shown 1. Filter element CLEAN Blow off dust by compressed air from air outlet side of the filter ele- ment.
  • Page 19 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 VENTILATION”.
  • Page 20 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.
  • Page 21 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.
  • Page 22 AIR CONDITIONING (OPTIONAL) 1B-13 COMPRESSION SYSTEM G16 LH steering vehicle 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.
  • Page 23 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. NOTE: Compressor assembly supplied from factory is filled up with following amount of oil. Amount of oil in compressor: 120 cm (120 cc, 7.5 in 2) For G16 engine: Install compressor temporarily to bracket, then install compres-...
  • Page 24 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.
  • Page 25 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.
  • Page 26 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.

  • Page 27: Special Tools

    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...
  • Page 28 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.
  • Page 29 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.
  • Page 30 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) For ease of adjustment after installation, make marking of tie-rod 2.
  • Page 31 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 7) Install tie-rod end lock nut and tie-rod end to tie-rod.

  • Page 32: Power Steering Pump

    POWER STEERING (P / S) SYSTEM 3B1-5 POWER STEERING PUMP 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) [A]: G16 Type engine...

  • Page 33: Special Tool

    3B1-6 POWER STEERING (P / S) SYSTEM TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts kg-m lb-ft G16 Type engine 40.0 Pump bracket bolt Pump bracket bolt J20 Type engine 18.5 Tie-rod (LH steering vehicle) 61.5 SPECIAL TOOL 09943-55010 Boot clamp plier...
  • Page 34 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.
  • Page 35 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.
  • Page 36 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.
  • Page 37 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.

  • Page 38: Front Suspension

    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 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.
  • Page 39 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-...
  • Page 40 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.
  • Page 41 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”...
  • Page 42 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) CAUTION: Do not pull wire harness or twist more than necessary when installing front wheel speed sensor.
  • Page 43 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.
  • Page 44 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.
  • Page 45 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.
  • Page 46 FRONT SUSPENSION 3D-9 TIGHTENING TORQUE SPECIFICATIONS 48 N 60 N...

  • Page 47: Rear Suspension

    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.

  • Page 48: Shock Absorber

    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.
  • Page 49 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.
  • Page 50 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.

  • Page 51: Wheels And Tires

    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.
  • Page 52 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.

  • Page 53: Oil Seal

    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 ON-VEHICLE SERVICE .

  • Page 54: Drive Shaft

    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.
  • Page 55 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.
  • Page 56 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.
  • Page 57 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.
  • Page 58 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.
  • Page 59 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.
  • Page 60 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.
  • Page 61 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).
  • Page 62 BRAKES 5-3 4) If rear brake pressure is not within specification, adjust it by changing stay “A” position as follows. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) “b” If rear brake pressure is higher than specification, move stay 3, “A”...
  • Page 63 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.
  • Page 64 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.
  • Page 65 BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3 2) Torque each bolt and nut to specification as indicated respec- tively in figure left. Tightening Torque (a): 23 N m (2.3 kg-m, 17.0 lb-ft) 1, (a) (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...
  • Page 66 5A-4 BRAKES PIPE / HOSE / MASTER CYLINDER TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts Fastening arts kg-m lb-ft LSPV mounting bolt 17 0 17.0 LSPV stay bolt...
  • Page 67 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.
  • Page 68 6-2 ENGINE GENERAL INFORMATION (G16 / J20 / H25 ENGINE) GENERAL INFORMATION Left hand steering vehicle 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.

  • Page 69: Table Of Contents

    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.

  • Page 70: General Description

    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...
  • Page 71 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.

  • Page 72: Diagnosis

    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”...

  • Page 73: B-1 Fuel Pump Circuit Check

    ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-5 B-1 FUEL PUMP CIRCUIT CHECK 1. Main fuse box 2. “IG” fuse 3. “FI” fuse 4. Ignition switch 5. “IG” circuit fuse 6. Main relay 7. Fuel pump relay 8. Fuel pump 9.

  • Page 74: Inspection Of Pcm (Ecm) And Its Circuit

    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.
  • Page 75 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.
  • Page 76 6E1-8 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) A/T VEHICLE TERMINALS CIRCUIT STANDARD RESISTANCE CONDITION 79 – 95 W A9 – A2 Main relay Battery disconnected and 75 – 110 W A22 – B20 A / C fan motor relay (if equipped) ignition switch ON 79 –...

  • Page 77: On-Vehicle Service

    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.
  • Page 78 6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 9) Check fuel leakage from injector nozzle. Do not operate injector 1. Injector for this check (but fuel pump should be at work). 2. Vinyl tube 3. Less than one fuel If fuel leaks more than the following specifications, replace.

  • Page 79: Electronic Control System

    ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) 6E1-11 ELECTRONIC CONTROL SYSTEM Left-hand steering vehicle 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.

  • Page 80: Fuel Pump Relay (Inspection)

    6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (G16 / J20 ENGINE) FUEL PUMP RELAY Left-hand steering vehicle 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.

  • Page 81: Charging 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.
  • Page 82 6H-2 CHARGING SYSTEM GENERAL DESCRIPTION GENERATOR [70 A type] 1. Pulley 6. Field coil : Generator output (Battery terminal) 2. Pulley nut 7. Regulator : Ground 3. Rotor fan 8. Brush IG : Ignition terminal 4. Stator coil 9. Front housing : Lamp terminal 5.

  • Page 83: Specifications

    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) Load Test Rated Capacity (AH/5HR, 12 Volts) 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...

  • Page 84: Automatic Transmission

    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.
  • Page 85 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.
  • Page 86 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”...
  • Page 87 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.

  • Page 88: Lighting 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.
  • Page 89 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 Type B 1. Hazard relay 2. Junction box 3. Fuse box...
  • Page 90 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.

  • Page 91: Combination Meter

    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.
  • Page 92 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.

  • Page 93: Windshield Wiper

    8D-2 WINDOWS, MIRRORS, SECURITY AND LOCKS ON-VEHICLE SERVICE Type A WINDSHIELD WIPER INSPECTION Wiper Motor 1) As illustrated, use a 12 V battery to connect its (+) terminal to ter- minal “A”, and its (–) terminal to Black lead wire. Type B If motor rotates at a low revolution speed of 45 to 55 rpm, it is proper.
  • Page 94 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.

  • Page 95: Body Structure

    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.

  • Page 96: Rear Bumper

    BODY SERVICE 9-3 REAR BUMPER 1. Rear bumper 2. Rear bumper member 3. Rear bumper garnish (if equipped)

  • Page 97: Body Dimensions

    9-4 BODY SERVICE BODY DIMENSIONS Canvas top model Garnish installation clip hole b (b’). Front end of front windshield lower installation section c (c’). Front end of front windshield upper installation section Hole in F door lower hinge at rear Trim installation clip hole f (f’).
  • Page 98 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 7 jig hole e. Scuff installation hole (rearmost end) f. Door striker lower section installation hole g.
  • Page 99 9-6 BODY SERVICE a (a’). Trim installation clip hole Installation hole in uppermost part of upper hinge Installation hole in outside part of lower hinge 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’).

  • Page 100: Seat

    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.

  • Page 101: Paint And Coatings

    9-8 BODY SERVICE PAINT AND COATING METAL REPLACEMENT PARTS FINISHING SEALANT APPLICATION AREA Canvas top model “A”: Apply sealant 1. Side body inner panel 5. Front floor panel “B”: Brush treatment 2. Rear wheel housing panel 6. Center floor member 3.
  • Page 102 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...
  • Page 103 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.
  • Page 104 BODY SERVICE 9-11 Be free from protrude of sealant outside from this line Sealant width “W”: more than 5 mm “A”: Apply sealant...
  • Page 105 9-12 BODY SERVICE UNDERCOATING/ANTI–CORROSION COMPOUND APPLICATION AREA Canvas top model...
  • Page 106 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 5. Front wheel housing “A”: Apply undercoating (PVC, 400 m or more) 6. Frame “B”: Additional applying of under coating 7.
  • Page 107 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...

  • Page 108: Convertible Top

    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.

  • Page 109: Exterior And Interior Trim

    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...

  • Page 110: Roof Trim

    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.
  • Page 111 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.

  • Page 112: Seat Belt

    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.

  • Page 113: Service Precautions

    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-...
  • Page 114 SEAT BELT 10A-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 elec- tric noise. Never carry the seat belt pretensioner by the wires or connector on the underside of the pretensioner.

  • Page 115: Air Bag System

    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.
  • Page 116 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.
  • Page 117 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.
  • Page 118 Prepared by Overseas Service Department 1st Ed. Sept., 1998 Printed in Japan Printing: Dec., 1998...

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