Page 27 of 698
0A-24 GENERAL INFORMATION
SYMBOLS
WIRE COLOR SYMBOLS
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure). SYMBOL DEFINITION SYMBOL DEFINITION
Tightening torque Apply SUZUKI BOND NO. 1216
99000-31160
Apply oil (engine, transmission, trans-
fer, differential)Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid)Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25010
Apply SUZUKI SUPER GREASE C
99000-25030Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25120Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110Do not reuse
Apply SUZUKI BOND NO. 1207C
99000-31150Note on reassembly
Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
GGRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green
Page 29 of 698
0A-26 GENERAL INFORMATION
Tightening torque chart :
Thread Diameter (Nominal Diameter) (mm)
4 5 6 8 10 12 14 16 18
StrengthA equivalent of 4T strength
fastenerN·m 1.5 3.0 5.5 13 29 45 65 105 160
kg-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16
lb-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0
A equivalent of 6.8 strength
fastener without flangeN·m 2.4 4.7 8.4 20 42 80 125 193 280
kg-m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28
lb-ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5
A equivalent of 6.8 strength
fastener with flangeN·m 2.4 4.9 8.8 21 44 84 133 203 298
kg-m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8
lb-ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5
A equivalent of 7T strength
fastenerN·m 2.3 4.5 10 23 50 85 135 210 240
kg-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24
lb-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0
A equivalent of 8.8 strength
fastener without flangeN·m 3.1 6.3 11 27 56 105 168 258 373
kg-m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3
lb-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0
A equivalent of 8.8 strength
fastener with flangeN·m 3.2 6.5 12 29 59 113 175 270 395
kg-m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5
lb-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0
✱: Self-lock nut
Page 63 of 698
1A-12 HEATER AND VENTILATION
AIR INLET BOX
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Remove glove box.
3) Disable air bag system by referring to “DISABLING AIR BAG
SYSTEM” in Section 10B. (if equipped)
4) Disconnect fresh air control cable (1) from air inlet box.
1. Resistance board 4. Fresh air duct packing 7. Air inlet door 10. Cable clamp
2. Air inlet case
: Apply sealant 99000 - 31160 to hatched part “A”
5. Door link 8. Clip : Do not reuse
3. Fresh air duct case 6. Heater unit packing 9. Dash packing
NOTE:
If vehicle equipped with A/C, refer to “COOLING UNIT” in
Section 1B.
1
72
8 1053
“A”
2
4
6
9
Page 65 of 698
1A-14 HEATER AND VENTILATION
INSTALLATION
Reverse removal procedure to install ventilation louver noting the
following instruction.
Be sure to install ventilation louver holder (1) to proper direc-
tion as shown.
REQUIRED SERVICE MATERIALS
MaterialRecommended SUZUKI product
(Part Number)Use
SealantSUZUKI BOND No. 1216B
99000 – 31160Air inlet box
Page 97 of 698
1B-32 AIR CONDITIONING (OPTIONAL)
COOLING UNIT (EVAPORATOR)
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.
3) Remove glove box.
1. A/C evaporator 6. Dash packing 11. O-ring
2. A/C evaporator temperature sensor 7. Packing 12. Door link
3. Expansion valve 8. Fresh air duct case 13. Lower packing
4. Evaporator case
: Apply sealant 99000-31160 to hatched part “A”.9. Clamp Do not reuse.
5. Cooling unit packing 10. Air inlet door
CAUTION:
Be careful not to damage A/C evaporator fins. If A/C
evaporator fin is bent, straighten it by using flat head
screwdriver or pair of pliers.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.
Page 108 of 698
AIR CONDITIONING (OPTIONAL) 1B-43
6) Tighten new front head mounting bolts (a), (b).
Tightening torque
Front head bolt (a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
Front head bolt (b) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
REQUIRED SERVICE MATERIAL
NOTE:
Be sure to use new front head mounting bolts.
Tighten bolt (a) first, and next (b).
MaterialRecommended SUZUKI product
(Part Number)Use
Compressor oil
(Refrigerant oil)COMPRESSOR OIL RS20 (150 cc)
99000-99088O-ring
Each component
Refrigerant REFRIGERANT DRUM (200 g)
95794-50G00Refrigerant charge
Sealant SUZUKI BOND No.1216B
99000-31160Cooling unit
Page 142 of 698
ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-1
6F1
6F2
6G
6H
6K
7A
7A1
3B1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B1
ELECTRICAL POWER STEERING (P/S) SYSTEM
CONTENTS
GENERAL DESCRIPTION .............................3B1-2
SYSTEM COMPONENTS ........................... 3B1-2
WIRING DIAGRAM ..................................... 3B1-3
DIAGNOSIS ....................................................3B1-4
ON-BOARD DIAGNOSTIC SYSTEM .......... 3B1-4
PRECAUTIONS IN DIAGNOSING
TROUBLES ................................................. 3B1-4
SYSTEM CHECK FLOW TABLE ................ 3B1-5
MALFUNCTION INDICATOR LAMP
(“EPS” WARNING LAMP) CHECK.............. 3B1-7
DTC CHECK ............................................... 3B1-8
DTC CLEARANCE ...................................... 3B1-9
SERIAL DATA LINK CIRCUIT CHECK ..... 3B1-10
DTC TABLE .............................................. 3B1-11
TABLE A - MALFUNCTION INDICATOR
LAMP DOES NOT COME ON AT
IGNITION SWITCH ON BUT LEAVING
ENGINE OFF ............................................ 3B1-13
TABLE B - MALFUNCTION INDICATOR
LAMP FLASHES AT IGNITION SWITCH
ON ............................................................. 3B1-15
TABLE C - MALFUNCTION INDICATOR
LAMP DOES NOT FLASH, JUST
REMAINS ON OR JUST REMAINS OFF
EVEN WITH DIAGNOSIS SWITCH
TERMINAL GROUNDED .......................... 3B1-15
DTC C1111 (DTC No.11) TORQUE
SENSOR MAIN CIRCUIT FAILURE ......... 3B1-16
DTC C1113 (DTC No.13) TORQUE
SENSOR MAIN AND SUB CIRCUIT
FAILURE ................................................... 3B1-16DTC C1115 (DTC No.15) TORQUE
SENSOR SUB CIRCUIT FAILURE........... 3B1-16
DTC C1114 (DTC No.14) TORQUE
SENSOR 5V POWER SUPPLY CIRCUIT
FAILURE ................................................... 3B1-17
DTC C1116 (DTC No.16) TORQUE
SENSOR 8V POWER SUPPLY CIRCUIT
FAILURE ................................................... 3B1-18
DTC C1121/C1123/C1124
(DTC No.21/23/24) VSS CIRCUIT
FAILURE ................................................... 3B1-19
DTC C1122 (DTC No.22) ENGINE
SPEED SIGNAL CIRCUIT FAILURE ........ 3B1-20
DTC C1141/C1142/C1143/C1144/C1145
(DTC No.41/42/43/44/45) MOTOR
CIRCUIT FAILURE ................................... 3B1-21
DTC C1151 (DTC No.51) CLUTCH
CIRCUIT FAILURE ................................... 3B1-22
DTC C1153(DTC No.53) P/S CONTROL
MODULE POWER SUPPLY CIRCUIT
FAILURE ................................................... 3B1-24
DTC C1152/C1154/C1155
(DTC No.52/54/55) P/S CONTROL
MODULE FAILURE .................................. 3B1-24
TROUBLE DIAGNOSIS (FOR TROUBLE
NOT INDICATED BY ON BOARD
DIAGNOSTIC SYSTEM)........................... 3B1-25
INSPECTION OF P/S CONTROL
MODULE AND ITS CIRCUITS ................. 3B1-26
STEERING WHEEL PLAY
INSPECTION ............................................ 3B1-28 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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
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).
Page 153 of 698
3B1-12 ELECTRICAL POWER STEERING (P/S) SYSTEM
DTC (displayed
on SUZUKI scan
tool)“EPS” light flashing pattern
DTC (indicated
by “EPS” light
flashing pattern)Model DIAGNOSTIC ITEM DIAGNOSIS
NO DTC 12 NormalThis code appears
when none of the other
codes are identified.
C1111 11
Torque sensor
Diagnose trouble
according to “DIAG-
NOSTIC FLOW
TABLE” corresponding
to each code No. C1113 13
C1114 14
C1115 15
C1116 16
C1121 21
VSS signal C1123 23
C1124 24
C1122 22Engine speed sig-
nal
C1141 41
Motor C1142 42
C1143 43
C1144 44
C1145 45
C1151 51 Clutch
C1152 52
P/S control module C1154 54
C1155 55
C1153 53P/S control module
power supply
