
Downloaded from www.Manualslib.com manuals search engine 0A-1 General Information: 
General Information
General Information
General Description
AbbreviationsS7RS0B0101001
A:  
ABDC:  After Bottom Dead Center
ABS:   Anti-lock Brake System
AC:   Alternating Current
A/C:  Air Conditioning
A-ELR:   Automatic-Emergency Locking Retractor
A/F:   Air Fuel Mixture Ratio
ALR:   Automatic Locking Retractor
API:   American Petroleum Institute
APP sensor:   Accelerator Pedal Position Sensor
A/T:   Automatic Transmission , Automatic Transaxle
AT D C :   After Top Dead Center
ATF:   Automatic Transmission  Fluid, Automatic 
Transaxle Fluid
B:  
B+:   Battery Positive Voltage
BBDC:   Before Bottom Dead Center
BCM:   Body Electrical Control Module
BDC:   Bottom Dead Center
BTDC:   Before Top Dead Center
C:  
CAN:   Controller Area Network
CKT:   Circuit
CKP Sensor:  Crankshaft Position Sensor
CMP Sensor:   Camshaft Position Sensor
CO:  Carbon Monoxide
CPP Switch:   Clutch Pedal Position Switch (Clutch 
Switch, Clutch Start Switch)
CPU:  Central Processing Unit
CRS:   Child Restraint System
D:  
DC:   Direct Current
DLC:   Data Link Connector (Assembly Line Diag. Link, 
ALDL, Serial Data Link, SDL)
DOHC:   Double Over Head Camshaft
DOJ:   Double Offset Joint
DRL:   Daytime Running Light
DTC:   Diagnostic Trouble Code (Diagnostic Code)
E:  
EBCM:   Electronic Brake Cont rol Module, ABS Control 
Module
EBD:   Electronic Brake Force Distribution
ECM:  Engine Control Module
ECT Sensor:  Engine Coolant Temperature Sensor  (Water Temp. Sensor, WTS)
EFE Heater:   Early Fuel Evaporation Heater (Positive 
Temperature Coefficient, PTC Heater)
EGR:  Exhaust Gas Recirculation
EGRT Sensor:   EGR Temperature Sensor (Recirculated 
Exhaust Gas Temp. Sensor, REGTS)
ELR:  Emergency Locking Retractor
ESP ®:  Electronic Stability Program
EPS:   Electronic Power Steering
EVAP:  Evaporative Emission EVAP Canister:  
Evaporative Emission Canister 
(Charcoal Canister)
F:  
4WD:   4 Wheel 
 Drive
G:  
GEN:   Generator
GND:   Ground
GPS:   Global Positioning System
H:  
HVAC:   Heating, Ventilating and Air Conditioning
HC:   Hydrocarbons
HO2S:   Heated Oxygen Sensor
I:  
IAC Valve:   Idle Air Control Valve (Idle Speed Control 
Solenoid Valve, ISC Solenoid Valve)
IAT Sensor:   Intake Air Temperature Sensor (Air 
temperature Sensor, ATS)
ICM:   Immobilizer Control Module
IG:   Ignition
ISC Actuator:  Idle Speed Control Actuator
L:  
LH:   Left Hand
LHD:   Left Hand Drive Vehicle
LSPV:   Load Sensing Proportioning Valve
M:  
MAF Sensor:  Mass Air Flow Sensor (Air Flow Sensor,  AFS, Air Flow Meter, AFM)
MAP Sensor:   Manifold Absolute  Pressure Sensor 
(Pressure Sensor, PS)
Max:   Maximum
MFI:   Multiport Fuel Injection (Mu ltipoint Fuel Injection)
Min:   Minimum
MIL:   Malfunction Indicator  Lamp (“SERVICE ENGINE 
SOON” Light)
M/T:   Manual Transmission, Manual Transaxle
N:  
NOx:   Nitrogen Oxides
O:  
OBD:   On-Board Diagnostic System (Self-Diagnosis 
Function)
O/D:   Overdrive
OHC:   Over Head Camshaft
O2S:   Oxygen Sensor
P:  
PCM:   Powertrain Control Module
PCV:   Positive Crankcase Ventilation
PNP:   Park / Neutral Position
P/S:   Power Steering
PSP Switch:   Power Steering Pressure Switch (P/S 
Pressure Switch)
R:  
RH:   Right Hand
RHD:   Right Hand Drive Vehicle
S:  
SAE:   Society of Automotive Engineers  

Downloaded from www.Manualslib.com manuals search engine General Information:  0A-2
SAS:  Steering Angle Sensor
SDM:  Sensing and Diagnostic Module (Air Bag  Controller, Air bag Control Module)
SDT:  Smart Diagnostic Tester
SFI:   Sequential Multipor t Fuel Injection
SOHC:  Single Over Head Camshaft
T:  
TBI:   Throttle Body Fuel Injection (Single-Point Fuel 
Injection, SPI)
TCC:   Torque Converter Clutch
TCM:   Transmission Control Module (A/T Controller, A/T 
Control Module)
TDC:   Top Dead Center
TP Sensor:   Throttle Position Sensor TVV:  
Thermal Vacuum Valve (Thermal Vacuum 
Switching Valve, TVSV, Bi metal Vacuum Switching 
Valve, BVSV)
TWC:   Three Way Catalytic Converter (Three Way 
Catalyst)
2WD:   2 Wheel Drive
U:  
USB:   Universal Serial Bus
V:  
VIN:   Vehicle Identification Number
VSS:   Vehicle Speed Sensor
VVT:   Variable Valve Timing (Camshaft Position Control)
W:  
WU-OC:   Warm Up Oxidation  Catalytic Converter
WU-TWC:   Warm Up Three Way Catalytic Converter
SymbolsS7RS0B0101002
Wire Color SymbolsS7RS0B0101003
Symbol Definition SymbolDefinition
Tightening torque Apply SUZUKI BOND NO. 1216B
99000-31230
Apply oil (engine, transmission, transfer, 
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
99000-25011
Apply SUZUKI SUPER GREASE C
99000-25030 Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050 Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25121 Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110 Do not reuse
Apply SUZUKI BO ND NO. 1207F
99000-31250 Note on reassembly
Apply SUZUKI BO ND NO. 1217G
99000-31260
Symbol Wire Color SymbolWire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue RRED Red
Br BRN Brown WWHT White
G GRN Green YYEL Yellow
Gr GRY Gray PPNK Pink
Lbl LT BLU Light blueVPPL Violet
Lg LT GRN Light green  

Downloaded from www.Manualslib.com manuals search engine 0A-3 General Information: 
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 sy mbols (i.e. “GRN/YEL”). The first symbo l 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).
Fasteners InformationS7RS0B0101004
Metric Fasteners
Most of the fasteners used for this vehicle are JIS-
defined and ISO-defined metric fasteners. When 
replacing any fasteners, it is most important that 
replacement fasteners be the correct diameter, thread 
pitch and strength.
CAUTION! 
Even when the nominal diameter (1) of thread 
is the same, the thread pitch (2) or the width 
across flats (3) may vary between ISO and 
JIS. Refer to JIS-TO-ISO Main Fasteners 
Comparison Table below for the difference.
Installing a mismatched bolt or nut will cause 
damage to the thread.
Before installing, check the thread pitch for 
correct matching and then tighten it by hand 
temporarily. If it is tight, recheck the thread 
pitch.
 
JIS-TO-ISO Main Fasteners Comparison Table Fastener Strength Identification
Most commonly used metric fastener strength property 
classes are 4T, 6.8, 7T, 8.8 and radial line with the class 
identification embossed on the head of each bolt. Some 
metric nuts will be marked with punch, 6 or 8 mark 
strength identification on the nut face. Figure shows the 
different strength markings.
When replacing metric fasteners, be careful to use bolts 
and nuts of the same strength or greater than the original 
fasteners (the same number marking or higher). It is 
likewise important to select replacement fasteners of the 
correct diameter and thread 
pitch. Correct replacement 
bolts and nuts are available through the parts division.
Metric bolts: Identification class numbers or marks 
correspond to bolt strength (increasing numbers 
represent increasing strength).
I2RH01010010-01
Nominal diameter
M6 M8 M10 M12 M14
JIS Thread pitch 1.0 1.25 1.25 1.25 1.5
Width across flats 10 12 14 17 19
ISO Thread pitch 1.0 1.25 1.5 1.5 1.5
Width across flats 10 13 16 18 21
I4RH0A010005-01
1. Nut strength identification
I5RH01010001-01  

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication:  0B-5
4) Screw new filter on oil filter stand by hand until the filter O-ring contacts mounting surface.
CAUTION! 
To tighten oil filter prop erly, it is important to 
accurately identify the position at which filter 
O-ring first contacts mounting surface.
 
5) Tighten the filter (1) 3/4 tu rn from the point of contact 
with the mounting surface using an oil filter wrench 
(2).
Tightening torque
Oil filter (b):  14 N·m (1 .4 kgf-m, 10.5 lb-ft) for 
reference
6) Replenish oil until oil leve l is brought to FULL level 
mark on dipstick (oil pan and oil filter capacity). The 
filler inlet is at the top of  the cylinder head cover. It is 
recommended to use engine oil of SG, SH, SJ, SL or 
SM grade. Select the appropriate oil viscosity 
according to the proper engine oil viscosity chart [A].
NOTE
Engine oil capacity is specified as the 
following.
However, note that the amount of oil required 
when actually changing oil may somewhat 
differ from the data depending on various 
conditions (temperature, viscosity, etc.).
 
Engine oil specification
Oil pan capacity: About 3.7 liters (7.8 / 6.5 US / 
lmp pt.)
Oil filter capacity: About 0.2 liter (0.4 / 0.3 US / 
lmp pt.)
Others: About 0.3 liter (0 .6 / 0.5 US / lmp pt.)
Total: About 4.2 liters (8.9 / 7.4 US / lmp pt.) 7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait 
another 5 minutes before checking oil level. Add oil, 
as necessary, to bring oil le vel to FULL level mark (1) 
on dipstick.
Engine Coolant ChangeS7RS0B0206005
WARNING! 
To help avoid danger of being burned, do not 
remove radiator cap while engine and 
radiator are still hot. Scalding fluid and steam 
can be blown out under pressure if cap is 
taken off too soon.
 
CAUTION! 
When changing engine coolant, use mixture 
of 50% specified water and 50% ANTIFREEZE 
/ ANTICORROSION COOLANT for the 
purpose of corrosion protection and 
lubrication.
 
Change engine coolant with new one referring to 
“Cooling System Flush and Refill in Section 1F”.
IYSQ01020010-01
Co
Fo-30
-22 -20
-4 -10
14 32 50 68 86 104 010203040
5W-30
20W-40
15W-40
10W-30, 10W-40
[A]
I7RS0B020001-02
2. Low level mark (hole)
IYSQ01020012-01  

Downloaded from www.Manualslib.com manuals search engine Table of Contents 1-iii
EVAP Canister Purge Valve and Its Circuit 
Inspection.......................................................... 1B-2
Vacuum Passage Inspection .............................. 1B-3
Vacuum Hose and Purge Valve Chamber  Inspection.......................................................... 1B-3
EVAP Canister Purge Valve  Inspection .............. 1B-3
EVAP Canister Inspection ... ................................ 1B-4
EGR Valve Removal and Installation .................. 1B-4
EGR Valve Inspection ......................................... 1B-4
PCV Hose Inspection .......................................... 1B-4
PCV Valve Inspection ......................................... 1B-5
Special Tools and Equipmen t ............................. 1B-5
Special Tool ........................................................ 1B-5
Engine Electrical Devices .. ..................... 1C-1
Repair Instructions .............................................. 1C-1
ECM Removal and Installation ............................ 1C-1
MAP Sensor Inspection ...................................... 1C-2
Electric Throttle Body  Assembly On-Vehicle 
Inspection.......................................................... 1C-2
Electric Throttle Body System Calibration ........... 1C-5
APP Sensor Assembly On-V ehicle Inspection .... 1C-5
APP Sensor Assembly Removal and  Installation ......................................................... 1C-5
APP Sensor Assembly Inspection ...................... 1C-6
ECT Sensor Removal and In stallation ................ 1C-6
ECT Sensor Inspection ....................................... 1C-7
HO2S-1 and HO2S-2 Heater On-Vehicle  Inspection.......................................................... 1C-7
HO2S-1 and HO2S-2 Removal and  Installation ......................................................... 1C-7
CMP Sensor Removal and In stallation ............... 1C-8
Camshaft Position (CMP) Se nsor Inspection ...... 1C-8
CKP Sensor Removal and Installation ................ 1C-9
CKP Sensor Inspection ....................................... 1C-9
Knock Sensor Removal and Installation ........... 1C-10
Main Relay, Fuel Pump  Relay and Starting 
Motor Control Relay Inspection....................... 1C-10
MAF and IAT Sensor On-Vehicle Inspection .... 1C-11
MAF and IAT Sensor Removal and  Installation ....................................................... 1C-11
MAF and IAT Sensor Inspection ....................... 1C-12
Electric Load Current Sensor On-Vehicle  Inspection........................................................ 1C-12
Specifications ..................................................... 1C-13
Tightening Torque Specifications ...................... 1C-13
Engine Mechanical ......... ......................... 1D-1
General Description ............................................. 1D-1
Engine Construction Description ......................... 1D-1
Camshaft Position Control (VVT Variable Valve Timing) System Description .................... 1D-2
Diagnostic Information and Procedures ............ 1D-4 Compression Check ............................................ 1D-4
Engine Vacuum Check ....................................... 1D-5
Valve Lash (Clearance) Inspection ..................... 1D-6
Repair Instructions .............................................. 1D-9 Air Cleaner Components ..................................... 1D-9
Air Cleaner Element Removal and Installation .... 1D-9 Air Cleaner Element Ins
pection and Cleaning ..1D-10
Cylinder Head Co ver Removal and 
Installation .......................................................1D-10
Throttle Body and  Intake Manifold 
Components ....................................................1D-12
Throttle Body On-Vehicle  Inspection.................1D-13
Electric Throttle Body Assembly Removal and  Installation .......................................................1D-13
Throttle Body Cleaning......................................1D-14
Intake Manifold Removal and Installation .........1D-14
Engine Mountings Components ........................1D-16
Engine Assembly Removal  and Installation ......1D-17
Timing Chain Cover Components .....................1D-20
Timing Chain Cover Removal and Installation ..1D-21
Timing Chain Cover Inspection .........................1D-23
Oil Control Valve Removal and Installation .......1D-23
Oil Control Valve Inspection ..............................1D-24
Timing Chain and Chain Tensioner  Components ....................................................1D-24
Timing Chain and Chain Tensioner Removal  and Installation ................................................1D-25
Timing Chain and Chain Tensioner Inspection ..1D-27
Camshaft, Tappet and Shim Components ........1D-28
Camshaft, Tappet and Shim Removal and  Installation .......................................................1D-29
Camshaft, Tappet and Shim Inspection ............1D-31
Valves and Cylinder Head  Components ...........1D-34
Valves and Cylinder Head Removal and 
Installation .......................................................1D-35
Valves and Cylinder Head Disassembly and  Assembly.........................................................1D-37
Valves and Valve Guides  Inspection.................1D-40
Cylinder Head Inspection . .................................1D-42
Valve Spring Inspection ....................................1D-43
Pistons, Piston Rings , Connecting Rods and 
Cylinders Components ....................................1D-44
Pistons, Piston Rings , Connecting Rods and 
Cylinders Removal and Installation .................1D-45
Pistons, Piston Rings , Connecting Rods and 
Cylinders Disassembly and Assembly ............1D-46
Cylinders, Pistons and Piston Rings  Inspection ........................................................1D-47
Piston Pins and Connecting  Rods Inspection ...1D-49
Crank Pin and Connecting Rod Bearings  Inspection ........................................................1D-50
Main Bearings, Cran kshaft and Cylinder 
Block Components ..........................................1D-53
Main Bearings, Cran kshaft and Cylinder 
Block Removal and Installa tion .......................1D-54
Crankshaft Inspection .......................................1D-57
Main Bearings Inspection . .................................1D-59
Sensor Plate Inspection ....................................1D-63
Rear Oil Seal Inspection ...................................1D-63
Flywheel Inspection...........................................1D-63
Cylinder Block Inspection ..................................1D-63
Specifications .................... .................................1D-64
Tightening Torque Specifications ......................1D-64
Special Tools and Equipmen t ...........................1D-66
Recommended Service Material .......................1D-66
Special Tool ......................................................1D-66  

Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis:  1A-11
Generator Control System DescriptionS7RS0B1101010
Generator Control System consists of a generator (1), electric load current sensor (7) located in the main fuse box (4) 
and ECM (5).
ECM controls generated electricity (adjusting  voltage of IC regulator (2)) so that it is suitable for the engine and electric 
load conditions. When the electric load increases quickly,  generation load of the generator increases quickly and 
causes idling to change. To  prevent this, ECM makes generated electricity volume vary gradually  to stabilize idling. 
Also, it reduces the engine load caused by temporary incr ease in electricity generation to cope with the engine 
condition (such as when accelerating).
Operation
ECM controls the generated voltage of the generator using “C” terminal (generator control terminal) duty, based on 
following information.
• Engine condition (ECT, vehicle speed, engine speed, TP, etc.) (9)
• Battery voltage (ECM backup power voltage) (10)
• Electric load condition (blower motor, rear defogger, head lights, radiator fan, A/C, etc.) (11)
• “FR” terminal output (field coil (3) cont rol duty) which indicates the operation rate  (electricity generation condition) of 
the generator.
Then the generator uses “C” terminal duty to regulate the adju sting voltage of the IC regulator with the field coil control 
duty so as to control its generated voltage (“B” terminal output voltage).
(For more information of the generated voltage, refer  to “Charging System Specifications in Section 1J”.)
Furthermore, the generation condition of the generator is co ntrolled to the optimum level by the electric load current 
sensor (7) which detects the electrical load condition (cur rent consumption) linearly even when a sudden electrical 
load variation occurs and thus the engine load is reduced.
B
IG
L
C
E
6
2
3
FR
5
12 13
14
1IG1
7
4
8
11
10 9
CMO
FCD
GCD 
I6RW0H110005-01
6. Ignition switch
12. BCM 14. CAN driver
8. Battery 13. Combination meter